Method for manufacturing resin product and device for manufacturing resin product

Abstract

Disclosed is a method for manufacturing a resin product using a fused deposition modeling-type 3D printer (3), wherein a first molded body (71) is produced using a first resin that has laser light absorption properties by means of the 3D printer (3). In addition, a second molded body (81) is produced, using the 3D printer (3), so as to be superposed on the first molded body (71) by supplying a second resin that has laser light transmissivity to the surface of the first molded body (71). The first molded body (71) and the second molded body (81) are welded to each other by irradiating laser light along a path that extends from the second molded body (81) side to the first molded body (71) through an irradiation region between the first molded body (71) and the second molded body (83).

Description

Resin product manufacturing method and resin product manufacturing device CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This international application claims the benefit of Japanese Patent Application No. 2023-148515, filed with the Japan Patent Office on September 13, 2023, the entire disclosure of which is incorporated herein by reference.

[0002] The present disclosure relates to a technique for manufacturing a resin product using a three-dimensional printer.

[0003] BACKGROUND ART Conventionally, a technique for manufacturing a three-dimensional resin product using a fused deposition modeling (FMD) three-dimensional printer (i.e., a 3D printer) has been known (see, for example, Patent Document 1).

[0004] Specifically, the resin that is the material for the resin product is melted at high temperature, the molten resin is ejected in a string-like shape from a molding nozzle, and the string-like parts are layered and molded into a three-dimensional shape to produce the resin product.

[0005] JP 2018-62128 A

[0006] However, as a result of detailed investigation by the inventors, the following problems were found in the conventional techniques.

[0007] As described above, when an FMD 3D printer is used to supply resin in string-like (e.g., cylindrical) form and stack it to form a three-dimensional shape, there are few interfaces (i.e., joints) where the stacked string-like parts come into contact, which reduces the strength at the interfaces, resulting in a problem of reduced strength of the resin product.

[0008] Furthermore, when resin is layered in a string-like manner, the condition of the string-like portion of the lower layer (for example, the degree of solidification) is not constant, and therefore the adhesive state of the string-like portion is not constant, which also means that the strength at the interface, and therefore the strength of the resin product, may not be sufficient.

[0009] One aspect of the present disclosure aims to provide a technique that can increase the strength of a resin product manufactured using a fused deposition modeling three-dimensional printer.

[0010] a) One aspect of the present disclosure relates to a manufacturing method for manufacturing a resin product using a fused deposition modeling three-dimensional printer that supplies molten resin in a string-like form from a modeling nozzle to create a molded body.

[0011] In this method for manufacturing a resin product, a first molded body is produced using a first resin that is laser-absorbent, a second resin that is laser-transparent is supplied to the surface of the first molded body, and a second molded body is produced so as to be laminated on the first molded body. Laser light is then irradiated from the second molded body side along a path that passes through an irradiation area between the first and second molded bodies and reaches the first molded body, thereby welding the first molded body and the second molded body together.

[0012] This configuration can increase the strength of resin products manufactured using a fused deposition modeling three-dimensional printer.

[0013] In other words, in the present disclosure, the first molded body can be effectively heated by irradiating the laser light from the second molded body side along a path that passes through the irradiation area between the first molded body and the second molded body and reaches the first molded body. This allows the surface of the first molded body to melt. Furthermore, since the second molded body is stacked on the first molded body, the heat from the heated first molded body is transferred to the second molded body. This allows the surface of the second molded body to be heated, and therefore the surface of the second molded body to melt as well. In this way, by melting the first molded body and the second molded body, the first molded body and the second molded body can be welded together.

[0014] Then, by welding the first molded body and the second molded body in this way, a resin product is obtained in which the first molded body and the second molded body are firmly joined together.

[0015] b) Another aspect of the present disclosure relates to a manufacturing apparatus for manufacturing resin products using a fused deposition modeling three-dimensional printer that supplies molten resin in a string-like form from a modeling nozzle to create a molded body.

[0016] In this resin product manufacturing device, the three-dimensional printer is equipped with a molding control unit configured to control the operation of the molding nozzle to supply a first resin that is laser light absorbent to create a first molded body, and a lamination control unit configured to control the operation of the molding nozzle to supply a second resin that is laser light transparent to the surface of the first molded body to create a second molded body to be laminated on the first molded body.

[0017] The manufacturing apparatus includes a laser device having a laser irradiation unit that irradiates laser light.

[0018] The laser device is equipped with a laser control unit configured to control the operation of the laser irradiation unit and irradiate the laser light along a path from the second molded body side, passing through the irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

[0019] This configuration can increase the strength of resin products manufactured using a fused deposition modeling three-dimensional printer.

[0020] In other words, in the present disclosure, the first molded body can be effectively heated by irradiating the laser light from the second molded body side along a path that passes through the irradiation area between the first molded body and the second molded body and reaches the first molded body. This allows the surface of the first molded body to melt. Furthermore, since the second molded body is stacked on the first molded body, the heat from the heated first molded body is transferred to the second molded body. This allows the surface of the second molded body to be heated, and therefore the surface of the second molded body to melt as well. In this way, by melting the first molded body and the second molded body, the first molded body and the second molded body can be welded together.

[0021] Then, by welding the first molded body and the second molded body in this way, a resin product is obtained in which the first molded body and the second molded body are firmly joined together.

[0022] c) Yet another aspect of the present disclosure relates to a manufacturing apparatus for manufacturing resin products using a fused deposition modeling three-dimensional printer that supplies molten resin in a string-like form from a modeling nozzle to create a molded body.

[0023] This resin product manufacturing apparatus includes, as the three-dimensional printer, a molding device equipped with a molding control unit configured to control the operation of the molding nozzle and supply a first resin that is laser light absorbent to create a first molded body, and a lamination device equipped with a lamination control unit configured to control the operation of the molding nozzle and supply a second resin that is laser light transparent to the surface of the first molded body to create a second molded body to be laminated on the first molded body.

[0024] The lamination device includes a laser device having a laser irradiation unit that irradiates laser light, and a laser control unit configured to control the operation of the laser irradiation unit to irradiate the laser light along a path from the second molded body side, passing through an irradiation region between the first molded body and the second molded body, and to reach the first molded body, thereby welding the first molded body and the second molded body.

[0025] This configuration can increase the strength of resin products manufactured using a fused deposition modeling three-dimensional printer.

[0026] In other words, in the present disclosure, the first molded body can be effectively heated by irradiating the laser light from the second molded body side along a path that passes through the irradiation area between the first molded body and the second molded body and reaches the first molded body. This allows the surface of the first molded body to melt. Furthermore, since the second molded body is stacked on the first molded body, the heat from the heated first molded body is transferred to the second molded body. This allows the surface of the second molded body to be heated, and therefore the surface of the second molded body to melt as well. In this way, by melting the first molded body and the second molded body, the first molded body and the second molded body can be welded together.

[0027] Then, by welding the first molded body and the second molded body in this way, a resin product is obtained in which the first molded body and the second molded body are firmly joined together.

[0028] Furthermore, since the present disclosure includes a molding device and a lamination device, it is possible to produce a first molded body using the molding device and then produce a second molded body by laminating it on the first molded body using the lamination device, which has the advantage of improving the flexibility of the manufacturing process.

[0029] FIG. 1A is a front view showing a resin product manufacturing apparatus of a first embodiment, and FIG. 1B is a plan view showing the configuration of a 3D printer used in the resin product manufacturing apparatus. FIG. 1B is a block diagram showing the electrical configuration of a manufacturing control device, etc. in the first embodiment. FIG. 3A, FIG. 3B, and FIG. 3C are perspective views showing a resin product manufacturing method of the first embodiment. FIG. 4A, FIG. 4B, and FIG. 4C are front views showing enlarged main parts of the resin product manufacturing method of the first embodiment. FIG. 1C is a flowchart showing processing performed by the manufacturing control device of the first embodiment. FIG. 1D is a perspective view showing a laminate in Modification 1. FIG. 7A is a front view showing a shaping nozzle equipped with a laser irradiation unit and a spray nozzle in Modification 3, and FIG. 7B is a plan view showing a shaping nozzle equipped with a laser irradiation unit and a spray nozzle. FIG. 1E is a perspective view showing a resin product manufacturing method of a second embodiment. FIG. 1F is a front view showing a resin product manufacturing apparatus of a third embodiment.

[0030] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings.

[0031] 1. First Embodiment In this first embodiment, a technique for manufacturing a resin product using a fused deposition modeling (FMD) three-dimensional printer will be described.

[0032] 1A , a resin product manufacturing apparatus (hereinafter referred to as manufacturing apparatus) 1 according to the first embodiment mainly includes a configuration 3 that functions as a fused deposition modeling three-dimensional printer (hereinafter referred to as 3D printer), a configuration 5 for irradiating laser light (hereinafter referred to as laser apparatus), a configuration 7 for injecting high-pressure gas (hereinafter referred to as gas apparatus), and a manufacturing control device 9 that controls the operation of the manufacturing apparatus 1.

[0033] Each component of the manufacturing apparatus 1 will be described below.

[0034] 1B , as is well known, a fused deposition modeling 3D printer 3 includes a modeling nozzle 11 that ejects resin from the tip, a movement mechanism 13 that moves the modeling nozzle 11 in three dimensions, a modeling stage 15 on which a molded body manufactured from the resin is placed, and a base 17 that supports the modeling stage 15, etc. Here, an example in which two modeling nozzles 11A and 11B are used will be described.

[0035] The three-dimensional directions refer to the X-, Y-, and Z-axis directions of an XYZ coordinate system, which is an orthogonal coordinate system. The XY plane is the horizontal plane, and the Z-axis direction is the vertical direction.

[0036] As is well known, the shaping nozzle 11 includes a through-hole that penetrates in the axial direction and a heater (not shown) disposed around the through-hole. The shaping nozzle 11 is configured such that a string-like solid resin material, for example, a filament, is supplied from the outside to the through-hole, heated and melted by the heater, and then supplied from an opening at the tip of the through-hole.

[0037] In addition to the method of supplying a filament, a method of melting a resin pellet and outputting it from the molding nozzle 11 can also be used, and there are no particular limitations as long as it is a fused deposition modeling method.

[0038] As the moving mechanism 13, a well-known configuration used in a 3D printer 3 can be adopted, and an example thereof will be described here.

[0039] For example, the moving mechanism 13, on the top surface of the base 17, in a plan view from the Z-axis direction (see Figure 1B), comprises four Z-axis members 21 which are pillars arranged at the four corners of the base 17 and extend in the Z-axis direction, each of the columnar Y-axis members (i.e., a pair of left and right Y-axis members) 23 which are horizontally suspended along the Y-axis direction between the two Z-axis members 21 on both sides in the Y-axis direction, and one columnar X-axis member 25 which is horizontally suspended along the X-axis direction between the left and right Y-axis members 23.

[0040] The Y-axis member 23 sandwiched between the pair of Z-axis members 21 is movable horizontally along the Z-axis direction. The pair of left and right Y-axis members 23 move in the Z-axis direction in the same manner while maintaining a parallel state.

[0041] Although not shown, the movement of the Y-axis member 23 is configured to be performed by a motor and gears and belts that transmit the driving force of the motor, as is well known.

[0042] The X-axis member 25 sandwiched between the pair of left and right Y-axis members 23 is movable in the Y-axis direction on the surface of the Y-axis member 23. Although not shown, the movement of the X-axis member 25 is configured to be performed by a motor, gears, belts, etc. that transmit the driving force of the motor, as is well known.

[0043] The two shaping nozzles (i.e., the first shaping nozzle 11A and the second shaping nozzle 11B) are attached to the X-axis member 23 so as to be movable in the X-axis direction. Although not shown, the movement of each shaping nozzle 11 is configured to be performed by a motor, a gear or a belt that transmits the driving force of the motor, or the like, as is well known.

[0044] While the 3D printer in which each modeling nozzle 11 moves in the X, Y, and Z axes has been described as an example, various known configurations of fused deposition modeling 3D printers can be employed. For example, a known configuration can be employed in which each modeling nozzle 11 is movable in the Z-axis direction and the Y-axis direction, and the modeling stage 15 is movable in the Y-axis direction. Alternatively, a known configuration can be employed in which each modeling nozzle 11 is movable in the X-axis direction and the Y-axis direction, and the modeling stage 15 is movable in the Z-axis direction. Alternatively, as is known, an X-axis member 25 may be disposed between a pair of left and right Z-axis members 21, and the Z-axis member 21 may be movable in the Y-axis direction, and the X-axis member 25 may be movable in the Z-axis direction, and each modeling nozzle 11 may be movable in the X-axis direction.

[0045] Although the case where two shaping nozzles 11 are used has been described here, it is also possible to use one shaping nozzle 11, as will be described later.

[0046] <Laser Device> As shown in FIG. 1A, the laser device 5 includes a laser irradiation unit 31 that irradiates laser light, and a first arm device 33 that moves the laser irradiation unit 31 in three-dimensional directions.

[0047] A multi-axis (for example, six-axis) robot arm can be used as the first arm device 33 , and the first arm device 33 is attached to the base 17 .

[0048] The laser irradiation unit 31 is attached to the tip of a first arm device 33, and by operating the first arm device 33, the three-dimensional position of the laser irradiation unit 31 and the irradiation direction of the laser light can be freely set.

[0049] For example, as described below, the laser irradiation unit 31 can be moved in the same direction as the movement direction of the second shaping nozzle 11B. In addition, by adjusting the inclination of the laser irradiation unit 31, the direction in which the laser light is irradiated can be set to a predetermined inclination (e.g., an inclination at a predetermined angle from the horizontal) as described below.

[0050] The laser irradiation unit 31 (i.e., laser) may be a solid-state laser such as a glass laser, a ruby ​​laser, a YAG laser, or a titanium sapphire laser, a He—Ne laser, or a CO ２ A gas laser such as a laser, a rare gas ion laser, or an excimer laser, or a semiconductor laser can be appropriately selected.

[0051] The laser irradiation unit 31 can be used with an output that takes into account the composition of the resin used in the resin product. That is, the laser irradiation unit 31 is used with an output that can melt the surface of the first molded body 71 (see FIG. 3, for example), which is the target to be heated by irradiating the laser light.

[0052] 1A, the gas device 7 includes an injection nozzle 35 that injects high-pressure gas and a second arm device 37 that moves the injection nozzle 35 in three-dimensional directions. The injection nozzle 35 is connected to a gas supply source (not shown) that supplies high-pressure gas.

[0053] A multi-axis (for example, six-axis) robot arm can be used as the second arm device 37 , and the second arm device 37 is attached to the base 17 .

[0054] The injection nozzle 35 is attached to the tip of a second arm device 37, and by operating the second arm device 37, the three-dimensional position of the injection nozzle 35 and the injection direction of the high-pressure gas can be freely set.

[0055] For example, as described below, the injection nozzle 35 can be moved in the same direction as the movement direction of the second shaping nozzle 11B. In addition, by adjusting the inclination of the injection nozzle 35, the direction in which the high-pressure gas is injected can be set to a predetermined inclination (e.g., an inclination inclined by a predetermined angle from the horizontal) as described below.

[0056] The pressure of the high-pressure gas may be, for example, twice the atmospheric pressure or more (for example, 0.2 MPa or more in absolute pressure).

[0057] [1-2. Electrical Configuration of Manufacturing Apparatus] Next, the electrical configuration of the manufacturing apparatus 1 will be described.

[0058] As shown in FIG. 2, the manufacturing control device 9 that controls the operation of the manufacturing device 1 includes an arithmetic processing unit 41 that performs various calculations related to the operation of the manufacturing device 1, etc.

[0059] The arithmetic processing unit 41 is mainly configured with a microcomputer (hereinafter referred to as "mc") having a CPU 43 and semiconductor memories (hereinafter referred to as "memories 49") such as a ROM 45 and a RAM 47. The arithmetic processing unit 41 may also be provided with an external storage device 51 such as a flash memory or a hard disk.

[0060] The various functions of the processing unit 41 are realized by the CPU 43 executing a program stored in a non-transient physical recording medium. In this example, the memory 49 corresponds to the non-transient physical recording medium storing the program. Furthermore, by executing this program, a method corresponding to the program is performed.

[0061] The number of microcomputers constituting the arithmetic processing unit 41 may be one or more. Furthermore, the method of realizing the various functions of the arithmetic processing unit 41 is not limited to software, and some or all of the elements may be realized using one or more pieces of hardware. For example, when the above functions are realized by electronic circuits that are hardware, the electronic circuits may be realized by digital circuits including a large number of logic circuits, analog circuits, or a combination of these.

[0062] Various actuators are connected to the manufacturing control device 9 to cause the manufacturing device 1 to perform operations.

[0063] For example, a first nozzle driving unit 53, a second nozzle driving unit 55, a laser driving unit 57, a first arm driving unit 59, a gas driving unit 61, a second arm driving unit 63, etc. are connected.

[0064] The first nozzle driving unit 53 is a circuit or the like that drives the first shaping nozzle 11A, and although not shown, as is well known, includes a plurality of motors that drive the first shaping nozzle 11A, a heater that melts the resin, etc. The motors include a motor that drives the Y-axis member 23 in the Z-axis direction, a motor that moves the X-axis member 25 in the Y-axis direction, a motor that drives the first shaping nozzle 11A in the X-axis direction, and a motor that drives a roller that supplies the filament.

[0065] The second nozzle driving unit 55 has a configuration similar to that of the first nozzle driving unit 53, and is a circuit that drives the second modeling nozzle 11B. Although not shown, the second nozzle driving unit 55 also includes a plurality of motors that drive the second modeling nozzle 11B, a heater that melts the resin, and the like, as is well known.

[0066] The laser driving unit 57 is a circuit or the like for driving the laser irradiation unit 31 to irradiate laser light from the tip of the laser irradiation unit 31 .

[0067] The first arm driving unit 59 is a circuit or the like that drives the first arm device 33 .

[0068] The gas driver 61 is a circuit or the like that drives the injection nozzle 35, and controls a valve (not shown) to control the injection state of the high-pressure gas (for example, whether to inject or stop injection).

[0069] The second arm driving unit 63 is a circuit or the like that drives the first arm device 33 , similar to the first arm driving unit 59 .

[0070] [1-3. Manufacturing Method] Next, a method for manufacturing a resin product carried out using the manufacturing apparatus 1 will be described.

[0071] (First Step: Step of Producing First Molded Body) In the first step, as shown in FIG. 3A , a first molded body 71 is produced using a first resin by the 3D printer 3 of the manufacturing device 1 .

[0072] In detail, first, a filament made of a first resin is supplied to the first modeling nozzle 11A, and the first resin is melted by a heater.

[0073] The first resin is a resin that has laser light absorption properties and has a higher laser light absorption property than the second resin. As the first resin, for example, a thermoplastic resin with a laser light transmittance of 5% or less can be used so as to have a high laser light absorption property. For example, the thermoplastic resin can be appropriately selected from resins such as polyamide and polybutylene terephthalate, or resins such as these blended with a colorant such as carbon black or various other additives.

[0074] Then, the first modeling nozzle 11A is moved according to the modeling data prepared in advance, and the molten first resin is supplied in a string shape (e.g., a cylindrical shape) from the tip of the first modeling nozzle 11A onto the upper surface of the modeling stage 15.

[0075] Specifically, the first object-forming nozzle 11A is moved along a movement direction (e.g., the Y-axis direction) based on the object-forming data, and the molten first resin is supplied in a cylindrical shape from the first object-forming nozzle 11A. The supplied first resin gradually solidifies, thereby forming a cylindrical portion (i.e., a first cylindrical portion) 73 that extends along the movement direction.

[0076] Similarly, another first cylindrical portion 73 is produced adjacent to the formed first cylindrical portion 73 by supplying the first resin in a cylindrical shape from the first shaping nozzle 11A as the first shaping nozzle 11A moves.

[0077] By repeating this operation, a first layer 71a is formed in which adjacent first cylindrical portions 73 are joined at interfaces K1 of a predetermined width (i.e., first interfaces that are interfaces made of the same type of resin). In other words, a plate-like horizontal portion (i.e., the first layer 71a) in which multiple first cylindrical portions 73 are lined up in the planar direction is formed.

[0078] Thereafter, a first cylindrical portion 73 is similarly laminated on a first cylindrical portion 73 of a part of the first layer 71a (for example, the left end in FIG. 3A ) to form a second layer 71b, and a first cylindrical portion 73 is similarly laminated on the second layer 71b to form a third layer 71c, and a first cylindrical portion 73 is similarly laminated on the third layer 71c to form a fourth layer 71d. Note that, for ease of understanding, a single first cylindrical portion 73 is used as an example for each of the second layer 71b to the fourth layer 71d, but this is not limiting and each layer may be composed of a plurality of first cylindrical portions 73.

[0079] By this operation, the first compact 71 is produced.

[0080] In detail, as shown enlarged in Figure 4A, the lower part of the first molded body 71 (i.e., the first layer 71a) has a plate-like shape in which a plurality of first cylindrical portions 73 extending along the movement direction (e.g., the Y-axis direction) are aligned and joined in a direction perpendicular to the movement direction (e.g., the X-axis direction).

[0081] As described above, adjacent first cylindrical portions 73 are in contact with each other at the band-shaped first interface K1. That is, immediately after the first cylindrical portions 73 are formed, the molten first resin is in the process of solidifying and is therefore soft, so adjacent first cylindrical portions 73 are joined at the first interface K1 having a certain width rather than at a single point. Note that this first interface K1 extends in the direction in which the first cylindrical portions 73 extend, i.e., along the movement direction of the first shaping nozzle 11A (e.g., the Y-axis direction).

[0082] Upper ends 75 of the first interfaces K1 of the first cylindrical portions 73 constituting the first layer 71a are exposed on a surface (e.g., the upper surface) of the first molded body 71 and extend in the movement direction along the first interfaces K1. Furthermore, recesses (i.e., grooves) 77 are formed between adjacent first cylindrical portions 73 along the upper ends 75 of the first interfaces K1, and these grooves 77 extend in the movement direction along the ends 75 of the first interfaces K1.

[0083] Similarly, one end 75 on one side (i.e., the right side in FIG. 4A ) of the first interface K1 of each first cylindrical portion 73 disposed perpendicular to the first layer 71 a is also exposed on a surface (e.g., the right surface) of the first molded body 71 and extends in the movement direction along the first interface K1. Furthermore, similarly, a groove 77 is formed between adjacent first cylindrical portions 73 along the end 75 of the first interface K1, and this groove 77 extends in the movement direction along the end 75 of the first interface K1.

[0084] (Second step: second molded body manufacturing step) In the second step, as shown in FIG. 3B , a second molded body 81 is manufactured on the surface of the first molded body 71 using a second resin by the 3D printer 3 of the manufacturing device 1.

[0085] In detail, first, a filament made of the second resin is supplied to the second shaping nozzle 11B, and the second resin is melted by a heater.

[0086] The second resin is a resin that is laser-transmissive and has a higher laser-transmissivity than the first resin. The second resin is a thermoplastic resin that has a lower laser-transmissivity than the first resin, for example, a laser-transmissivity of 25% or more. For example, a resin such as polyamide or polybutylene terephthalate, or a resin such as this blended with a clarifying agent or other additives that have a sufficiently low laser-transmissivity, can be appropriately selected.

[0087] Then, the second shaping nozzle 11B is moved according to the shaping data prepared in advance, and the molten second resin is supplied in a string-like shape (e.g., a cylindrical shape) from the tip of the second shaping nozzle 11B onto the upper surface of the first molded body 71.

[0088] In other words, when the second molded body 81 is stacked on top of the first molded body 71, as shown enlarged in Figure 4B, the second resin is supplied along the end 75 of the first interface K1 of the first molded body 71 in a shape that covers the end 75 of the first interface K1 and the groove 77.

[0089] Specifically, similarly to the first shaping nozzle 11A, the second shaping nozzle 11B is moved along a movement direction (e.g., the Y-axis direction) based on the shaping data, and the molten second resin is supplied from the second shaping nozzle 11B in a cylindrical shape. As the supplied second resin gradually solidifies, a cylindrical portion (i.e., a second cylindrical portion) 83 assumes a shape that extends along the movement direction and covers the end portion 75 and the groove 77 of the first interface K1.

[0090] Here, an example is shown of a second molded body 81 consisting of one second cylindrical portion 83, but as will be described later, a second molded body 81 consisting of multiple second cylindrical portions 83 may be formed by sequentially forming multiple second cylindrical portions 83, similar to the first molded body 71.

[0091] In addition, in this second process, when the second resin is supplied from the second shaping nozzle 11B to produce the second cylindrical portion 83 (i.e., the second molded body 81), high-pressure gas is sprayed from the spray nozzle 35 toward the second cylindrical portion 83.

[0092] The injection direction and injection position of the high-pressure gas are controlled by the second arm device 37 that holds the injection nozzle 35. In other words, since the driving state of the second shaping nozzle 11B, such as the position, is known, the injection nozzle 35 is moved along the moving direction of the second shaping nozzle 11B while injecting high-pressure gas from the injection nozzle 35. In other words, the injection nozzle 35 is driven so as to inject high-pressure gas along the second cylindrical portion 83 that is supplied from the second shaping nozzle 11B and gradually solidifies, i.e., toward the soft cylindrical second resin that becomes the second cylindrical portion 83.

[0093] The high-pressure gas can be sprayed in a direction inclined downward at a predetermined angle from the horizontal (e.g., the XY plane) in a plane perpendicular to the second cylindrical portion 83. For example, the spray angle can be in the range of 45°±30° downward from the horizontal (e.g., 45°).

[0094] By using such a spray direction, the second cylindrical portion 83 that is gradually solidifying can be pressed toward the boundary portion KB, which is the space surrounded by the cylindrical portions 73 and 83 on the periphery.

[0095] The pressure when the high-pressure gas is injected (i.e., the pressure pressing against the surface of the second cylindrical portion 83) can be, for example, at least twice the atmospheric pressure (e.g., an absolute pressure of 0.2 MPa or more). In other words, the pressure when the high-pressure gas presses against the second cylindrical portion 83 can be a pressure that can push a portion of the gradually solidifying second resin into the boundary portion KB, or a pressure that can move or deform the surface of the gradually solidifying second resin toward the pressing side.

[0096] High pressure gases include air, nitrogen gas, CO ２ Gas etc. can be used.

[0097] In this way, by forming the second molded body 81 on the surface of the first molded body 71, a laminate 85 can be obtained in which the second molded body 81 is laminated on the surface of the first molded body 71.

[0098] In the first embodiment, when manufacturing the second cylindrical portion 83 made of the second resin, high-pressure gas is sprayed onto the second cylindrical portion 83, but a configuration in which high-pressure gas is not sprayed can also be adopted.

[0099] (Third Step: Step of Producing a Welded Body) In the third step, as shown in FIG. 3C , the first compact 71 and the second compact 81 are heated with a laser beam to be welded together, thereby producing a welded body 91 .

[0100] In addition, the welding also includes the step of melting the resin, then lowering the temperature of the resin to solidify it, thereby integrating the first molded body 71 and the second molded body 81 (i.e., making them into a resin product).

[0101] That is, the first molded body 71 and the second molded body 81 are welded together by irradiating laser light from the laser irradiation unit 31 along a path that passes through the irradiation area between the first molded body 71 and the second molded body 81 from the second molded body 81 side and reaches the first molded body 71. The irradiation area is the range that is irradiated with laser light. In other words, the irradiation area is a range that is set so that the laser light passes between the first molded body 71 and the second molded body 81 when laser light is irradiated to the first molded body 71 from the second molded body 81 side.

[0102] The direction and position of the laser light irradiation are controlled by a first arm device 33 that holds the laser irradiation unit 31. In other words, since the position of the second molded body 81 (i.e., the second cylindrical portion 83) on the first molded body 71 is known, the laser irradiation unit 31 is moved along the direction in which the second cylindrical portion 83 extends while irradiating the laser light from the laser irradiation unit 31.

[0103] 4C , the direction of irradiation of the laser light can be, for example, a direction that is inclined downward at a predetermined angle from the horizontal (e.g., the XY plane) on a plane perpendicular to the second cylindrical portion 83. For example, the irradiation angle can be in a range of 45°±30° downward from the horizontal (e.g., 45°).

[0104] The range of irradiation with the laser light, i.e., the irradiation region as viewed from the direction in which the second cylindrical portion 83 extends (e.g., the Y-axis direction), includes a region including the interface K2 where the first cylindrical portion 73 of the first molded body 71 and the second cylindrical portion of the second molded body come into contact (i.e., the second interface K2, which is an interface made of resins with different properties). For example, this includes a pair of second interfaces K2 where certain second cylindrical portions 83 come into contact, and a region sandwiched between the pair of second interfaces K2 (e.g., a region including the boundary portion KB).

[0105] In this way, when the irradiation area is irradiated with laser light, the laser light passes through the second cylindrical portion 83 made of the second resin, which has high laser light transmittance, and is absorbed by the first cylindrical portion 73 made of the first resin, which has high laser light absorbency. This causes the surface temperature of the first cylindrical portion 73 in particular to rise, and the surface of the first cylindrical portion 73 gradually melts.

[0106] Furthermore, the heat on the surface of the first cylindrical portion 73 is transferred to the second cylindrical portion 83 with which it comes into contact via the second interface K2, causing the surface temperature of the second cylindrical portion 83 to rise and gradually melt the surface of the second cylindrical portion 83 as well.

[0107] As a result, the resins of the two cylindrical portions 73, 83, which are in contact at the second interface K2, melt and mix together, and at the same time, the molten resins enter the space at the boundary KB, mix, and become integrated. Then, when the laser light irradiation is completed, the temperatures of the two resins drop, and an integrated compatible portion SB is formed. In other words, the two cylindrical portions 73, 83 are firmly joined and integrated at the second interface K2 and the compatible portion SB. Note that, depending on the amount of melting of the two resins, a space may remain at the boundary KB.

[0108] In this way, by irradiating the laser light, more specifically by cooling to room temperature after the laser light irradiation, it is possible to obtain a welded body 91 in which the first molded body 71 and the second molded body 81 are welded together. Note that this welded body 91, i.e., the welded body 91 in which the temperature of the molten portion has dropped and solidified, corresponds to a resin product.

[0109] Furthermore, in the first embodiment, when irradiating the laser beam, high-pressure gas is injected toward the second cylindrical portion 83 in the same manner as in the second step. That is, high-pressure gas is injected from the injection nozzle 35 toward the second cylindrical portion 83 while irradiating the laser beam.

[0110] The injection direction and injection position of the high-pressure gas can be controlled under the same conditions as in the second step, and are controlled by the second arm device 37 that holds the injection nozzle 35 .

[0111] When injecting high-pressure gas, an injection direction is adopted that allows the high-pressure gas to be injected at the irradiation position on the irradiation target where the laser light is irradiated (i.e., the irradiation position on the second cylindrical portion 32). Specifically, the relationship between the irradiation direction of the laser light and the injection direction of the high-pressure gas can be coaxial, parallel, or at a predetermined angle (i.e., when the laser light is irradiated and the high-pressure gas is injected from different directions toward the same position). Of these, it is preferable that the irradiation direction of the laser light and the injection direction of the high-pressure gas are close to the same axis. Note that if they are not coaxial, it is preferable that the irradiation of the laser light and the injection of the high-pressure gas be performed as close as possible so that the high-pressure gas can be injected at the position where the laser light is irradiated.

[0112] The high-pressure gas is injected simultaneously with the laser beam irradiation. That is, the high-pressure gas is injected while the laser beam is being irradiated. However, the high-pressure gas may be injected before the laser beam irradiation.

[0113] The pressure at which the high-pressure gas is injected is the same as in the second step, but since the second cylindrical portion 83 from which the high-pressure gas is injected is in a solidified state, a pressure higher than that in the second step is preferable.

[0114] In other words, the irradiation of the laser light melts the surfaces of the first molded body 71 and the second molded body 81, which may temporarily reduce the bonding strength between the first molded body 71 and the second molded body 81. Therefore, when the surfaces of the first molded body 71 and the second molded body 81 melt, high-pressure gas is injected to press the second cylindrical portion 83 toward the first molded body 71, so that the first molded body 71 and the second molded body 81 do not separate.

[0115] The high-pressure gas can be sprayed from the upper right of FIG. 4C toward the second cylindrical portion 83, similar to the irradiation direction of the laser light, but can also be sprayed from the back side of the first molded body 71 opposite the second cylindrical portion 83 (for example, the lower left of FIG. 4C). In this case, the gas may be sprayed parallel to both the front and back sides of the first molded body 71 (for example, coaxially) so as to sandwich the second cylindrical portion 83. The gas may also be sprayed from only one of the front and back sides of the first molded body 71.

[0116] In the first embodiment, high-pressure gas is injected into the second cylindrical portion 83 when irradiating the laser light, but a configuration in which high-pressure gas is not injected can also be employed.

[0117] [1-4. Control Processing] Next, the processing performed in the first embodiment will be described with reference to the flowchart in FIG.

[0118] This process is carried out by the calculation processing unit 41.

[0119] As shown in FIG. 5 , in step (hereinafter, S) 100, the 3D printer 3 is driven and a first resin is output from the first modeling nozzle 11A to produce a first molded body 71 consisting of a plurality of first cylindrical portions 73.

[0120] In the following step S110, the 3D printer 3 is driven to output the first resin from the second modeling nozzle 11B onto the surface of the first molded body 71, thereby producing a second molded body 81 consisting of a second cylindrical portion 83.

[0121] When the second cylindrical portion 83 is produced, the injection nozzle 35 and the second arm device 37 are driven to inject high-pressure gas onto the second cylindrical portion 83 .

[0122] In the next step S120, the laser irradiation unit 31 and the first arm device 33 are driven to transmit the laser light through the second molded body 81 and irradiate the first molded body 71. At the same time, the injection nozzle 35 and the second arm device 37 are driven to inject high-pressure gas toward the second cylindrical portion 83. This causes the first molded body 71 and the second molded body 81 to be welded together, and the process is temporarily terminated.

[0123] [1-5. Effects] According to the first embodiment, the following effects can be obtained.

[0124] (1a) In this first embodiment, a first molded body 71 is produced using a first resin that is laser-absorbent, and a second resin that is laser-transparent is supplied to the surface of the first molded body 71 to produce a second molded body 81 that is laminated on the first molded body 71. Then, laser light is irradiated from the second molded body 81 side along a path that passes through an irradiation region between the first molded body 71 and the second molded body 81 and reaches the first molded body 71, thereby welding the first molded body 71 and the second molded body 81 together.

[0125] This configuration can increase the strength of resin products manufactured using the fused deposition modeling 3D printer 3.

[0126] That is, in the first embodiment, the first molded body 71 made of the first resin can be effectively heated by irradiating the laser beam from the second molded body 81 side through an irradiation area between the first molded body 71 and the second molded body 81 (e.g., an area including the second interface K2) and along a path to the first molded body 71. This allows the surface of the first molded body 71 to be melted. Furthermore, since the second molded body 81 is laminated on the first molded body 71, the heat of the heated first molded body 71 is transferred to the second molded body 81 via the second interface K2, etc. This allows the surface of the second molded body 81 to be heated, and therefore the surface of the second molded body 81 to be melted as well. In this way, the first molded body 71 and the second molded body 81 are melted, thereby welding the first molded body 71 and the second molded body 81 together.

[0127] Then, by welding the first molded body 71 and the second molded body 81 together in this manner, a resin product is obtained in which the first molded body 71 and the second molded body 81 are firmly joined together.

[0128] (1b) In this first embodiment, when the second resin is supplied to the surface of the first molded body 71, high-pressure gas is sprayed onto the supplied second resin so as to press the second resin toward the first molded body 71.

[0129] This improves the adhesion between the first molded body 71 and the second molded body, which has the advantage of improving the strength of the resin product produced.

[0130] (1c) In this first embodiment, when welding the first molded body 71 and the second molded body 81, high-pressure gas is sprayed onto the surface of the second molded body 81 so as to press the second molded body 81 toward the first molded body 71.

[0131] This improves the adhesion between the first molded body 71 and the second molded body, which has the advantage of improving the strength of the resin product produced.

[0132] (1d) In this first embodiment, when the second molded body 81 is laminated on the first molded body 71, the second resin is supplied in a shape that covers the end 75 of the first interface K1 of the first molded body 71 along the end 75 of the first interface K1, and when welding is performed, the second molded body 81 is welded to the first molded body 71 in an area that sandwiches the end 75 of the first interface K1 of the first molded body 71.

[0133] In other words, in this first embodiment, the second resin is supplied along the end 75 of the first interface K1, which is prone to weakening in strength, and the second molded body 81 is welded to the first molded body 71 in the range that sandwiches the end 75 of the first interface K1 of the first molded body 71, which has the advantage of improving the strength of the resin product produced.

[0134] [1-6. Correspondence] Next, the relationship between the first embodiment and the present disclosure will be described.

[0135] The manufacturing apparatus 1 corresponds to the manufacturing apparatus, the 3D printer 3 corresponds to the three-dimensional printer, the laser apparatus 5 corresponds to the laser apparatus, the gas apparatus 7 corresponds to the gas apparatus, the laser irradiation unit 31 corresponds to the laser irradiation unit, the first molded body 71 corresponds to the first molded body, and the second molded body 81 corresponds to the second molded body.

[0136] [1-7. Modifications] <Modification 1> As shown in FIG. 6 , in Modification 1, the first molded body 71 has a configuration in which a plurality of first cylindrical portions 73 are stacked, and the second molded body 81 also has a configuration in which a plurality of second cylindrical portions 83 are stacked.

[0137] In this modified example 1, when manufacturing a welded body 91 from a stack 85, as in the first embodiment, laser light is irradiated and high-pressure gas is sprayed from the upper left of the same figure, where multiple second cylindrical portions 83 are stacked.

[0138] This provides the same effects as in the first embodiment. <Modification 2> In the first embodiment, the first modeling nozzle 11A that outputs the first resin and the second modeling nozzle 11B that outputs the second resin are used, but a single modeling nozzle may be used.

[0139] For example, after supplying a first resin to the first shaping nozzle 11A to produce a first molded body 71, the first resin may be removed from the first shaping nozzle 11A, and then a second resin may be supplied to the first shaping nozzle 11A to produce a second molded body 81.

[0140] In the first embodiment, the laser irradiation unit 31 and the injection nozzle 35 are attached to the tip of the robot arm, but as shown in Fig. 7, the laser irradiation unit 31 and the injection nozzle 35 may be attached to the shaping nozzle (for example, the second shaping nozzle 11B).

[0141] 7B , the laser irradiation unit 31 and the injection nozzle 35 may be attached to both sides of the second shaping nozzle 11A in the Y-axis direction. In this case, the second shaping nozzle 11A may be provided with a rotation shaft 93 extending in the Y-axis direction, and the laser irradiation unit 31 and the injection nozzle 35 may be attached to this rotation shaft 93.

[0142] The laser irradiation unit 31 and the injection nozzle 35 may be rotatable around the rotation axis 93 by a predetermined angle α (for example, any angle downward from the horizontal in FIG. 7A).

[0143] The angles of the laser irradiation unit 31 and the injection nozzle 35 can be set to any angle by using a motor, gears, etc. (not shown).

[0144] With this configuration, by moving the second shaping nozzle 11A, which is freely movable in three-dimensional directions, the laser irradiation unit 31 and the injection nozzle 35 can also be moved to any position in the three-dimensional directions.

[0145] Furthermore, the irradiation angle of the laser light and the injection direction of the high-pressure gas can be set to desired angles by adjusting the rotation angles of the laser irradiation unit 31 and the injection nozzle 35 .

[0146] In addition to attaching the laser irradiation unit 31 and the injection nozzle 35 to the second shaping nozzle 11B, a moving device similar to the moving device 12 (i.e., the moving device that moves the second shaping nozzle 11B) above the second shaping nozzle 11B may be installed on the X-axis member 25, and the laser irradiation unit 31 and the injection nozzle 35 may be attached to this moving device.

[0147] [2. Second Embodiment] The second embodiment has the same basic configuration as the first embodiment, and therefore the following mainly describes the differences from the first embodiment. Note that the same reference numerals as those in the first embodiment indicate the same configuration, and reference is made to the preceding description.

[0148] In the second embodiment, the method for producing the second molded body 81 is different from that in the first embodiment.

[0149] As shown in Figure 8, in this second embodiment, the second resin is supplied in a string-like (e.g., cylindrical) shape from the second shaping nozzle 11B to the surface of the first molded body 71, which is similar to the first embodiment, more specifically, to the inside of the right-angle bent part of the first molded body 71 (i.e., the side with the smaller angle).

[0150] At this time, the second resin is supplied so as to straddle the horizontal and vertical portions of the first molded body 71, thereby forming a second cylindrical portion 83 shaped to straddle the horizontal and vertical portions.

[0151] In other words, when the second molded body 81 is laminated on the first molded body 71, the second resin is supplied in a shape that spans the ends 75 (i.e., each end 75 of the pair of first interfaces K1) of a certain first cylindrical portion 73 (i.e., the first cylindrical portion 73 at the corner) to form the second cylindrical portion 83.

[0152] That is, in this second embodiment, the second resin is supplied in a serpentine manner so as to straddle the horizontal and vertical portions of the first molded body 71 multiple times, thereby forming a second cylindrical portion 83 having a shape that straddles the horizontal and vertical portions in a serpentine manner multiple times.

[0153] Furthermore, after forming the second cylindrical portion 83 (i.e., the second molded body 81), as in the first embodiment, laser light is irradiated onto the irradiation area toward the second cylindrical portion 83, and high-pressure gas is sprayed to weld the first molded body 71 and the second molded body 81 together.

[0154] In this second embodiment, when producing the second molded body 81, a second shaping nozzle 11B having a configuration similar to that of the first embodiment can be used, but in order to easily produce a second molded body 81 having a serpentine shape in both the horizontal and vertical directions, a second shaping nozzle 11B whose spray direction can be freely set may also be used.

[0155] For example, as described above, the moving device may be attached to the X-axis member 25, and the second object-forming nozzle 11B may be attached to the moving device so as to be rotatable in a desired direction (for example, so as to be rotatable around the Z-axis and the Y-axis). Note that the second object-forming nozzle 11B can be rotatably driven by a configuration including a motor and gears.

[0156] Alternatively, a second shaping nozzle 11B may be attached to the tip of a robot arm to form the second cylindrical portion 83 having the serpentine shape described above.

[0157] The conditions for irradiating the laser light (for example, irradiation direction, irradiation timing, etc.) and the conditions for injecting the high-pressure gas (for example, irradiation direction, injection timing, pressure, etc.) can be the same as those in the first embodiment.

[0158] The second embodiment has the same effects as the first embodiment. Furthermore, in the second embodiment, the second cylindrical portion 83 is formed so as to straddle the horizontal and vertical portions of the first molded body 71, which has the advantage of increasing the strength of portions that tend to be weak (for example, portions that bend at right angles).

[0159] [3. Third Embodiment] The third embodiment has the same basic configuration as the first embodiment, and therefore the following description will mainly focus on the differences from the first embodiment. Note that the same reference numerals as those in the first embodiment indicate the same configuration, and reference is made to the preceding description.

[0160] In the third embodiment, separate devices are used to produce the first molded body 71 and the second molded body 81 .

[0161] In this third embodiment, as shown in Figure 9, the manufacturing apparatus 100 includes a molding apparatus 101 having the functions of a fused deposition modeling 3D printer used to produce the first molded body 71, and a lamination apparatus 103 having the functions of a fused deposition modeling 3D printer used to produce the second molded body 81.

[0162] The molding device 101 includes a first molding nozzle 11A similar to that of the first embodiment. Therefore, by outputting a first resin from the first molding nozzle 11A, a first molded body 71 can be manufactured on a first molding stage 15A.

[0163] The lamination device 103 includes the second shaping nozzle 11A, the laser irradiation unit 31, and the injection nozzle 35, which are similar to those in the first embodiment. Therefore, the first molded body 71 removed from the molding device 101 is placed on the second shaping stage 15B, and the second resin is output from the second shaping nozzle 11A onto the surface of the first molded body 71, thereby laminating the second molded body 81 on the surface of the first molded body 71.

[0164] Furthermore, similarly to the first embodiment, the first compact 71 and the second compact 81 can be welded together by irradiating them with laser light and injecting high-pressure gas.

[0165] The conditions for irradiating the laser light (for example, irradiation direction, irradiation timing, etc.) and the conditions for injecting the high-pressure gas (for example, irradiation direction, injection timing, pressure, etc.) can be the same as those in the first embodiment.

[0166] The third embodiment has the same effects as the first embodiment. Furthermore, in the third embodiment, separate devices are used to produce the first molded body 71 and the second molded body 81, which has the advantage of increasing the flexibility of the manufacturing process.

[0167] [4. Other Embodiments] Although the embodiments of the present disclosure have been described above, it goes without saying that the present disclosure is not limited to the above-described embodiments and can take on various forms.

[0168] (4a) The operation of the manufacturing apparatus described in this disclosure may be realized by a special purpose computer provided by configuring a processor and memory programmed to perform one or more functions embodied in a computer program.

[0169] Alternatively, the operations of the manufacturing apparatus described in this disclosure may be implemented by a special purpose computer provided by configuring a processor with one or more special purpose hardware logic circuits.

[0170] Alternatively, the operation of the manufacturing apparatus described in this disclosure may be implemented by one or more dedicated computers configured by a combination of a processor and memory programmed to perform one or more functions and a processor configured with one or more hardware logic circuits.

[0171] The computer program may be stored as instructions executed by a computer on a computer-readable non-transitory storage medium. The method for realizing the functions of the manufacturing apparatus does not necessarily have to include software, and all of the functions may be realized using one or more pieces of hardware.

[0172] (4b) In addition to the manufacturing apparatus described above, the present disclosure can also be realized in various forms, such as a configuration that includes the manufacturing apparatus as a component, a program for causing the computer of the manufacturing apparatus to function, a non-transferable tangible recording medium such as a semiconductor memory on which the program is recorded, and a manufacturing method.

[0173] (4c) Multiple functions possessed by one component in each of the above embodiments may be realized by multiple components, or one function possessed by one component may be realized by multiple components. Furthermore, multiple functions possessed by multiple components may be realized by one component, or one function realized by multiple components may be realized by one component. Furthermore, part of the configuration of each of the above embodiments may be omitted. Furthermore, at least part of the configuration of each of the above embodiments may be added to or substituted for the configuration of another embodiment. [Technical Ideas Disclosed in the Specification] [Item 1] A manufacturing method for manufacturing a resin product using a fused deposition modeling three-dimensional printer (3) that supplies molten resin in a string-like form from a molding nozzle (11) to manufacture a molded body, the method comprising: manufacturing a first molded body (71) using a first resin that is laser light absorbent; supplying a second resin that is laser light transmissive to the surface of the first molded body to manufacture a second molded body (81) so as to be laminated on the first molded body; and irradiating laser light from the second molded body side along a path that passes through an irradiation area between the first molded body and the second molded body and leads to the first molded body, thereby welding the first molded body and the second molded body together.

[0174] [Item 2] The method for manufacturing a resin product according to Item 1, wherein, when the second resin is supplied to the surface of the first molded body, a pressing gas is sprayed onto the supplied second resin so as to press the second resin toward the first molded body.

[0175] [Item 3] The method for manufacturing a resin product according to Item 1 or 2, wherein when welding the first molded body and the second molded body, a pressing gas is blown onto the surface of the second molded body so as to press the second molded body against the first molded body side and / or so as to press the first molded body against the surface of the first molded body.

[0176] [Item 4] A method for manufacturing a resin product according to any one of items 1 to 3, wherein the first molded body has an interface where a plurality of string-like portions made of the first resin abut against each other, and an end of the interface is exposed on a surface of the first molded body; when stacking the second molded body on the first molded body, the second resin is supplied in a shape that straddles the end of the interface of the first molded body; and when welding is performed, the second molded body is welded to the first molded body within a range that sandwiches the end of the interface of the first molded body.

[0177] [Item 5] A method for manufacturing a resin product according to any one of items 1 to 3, wherein the first molded body has an interface where a plurality of string-like portions made of the first resin abut against each other, and an end of the interface is exposed on a surface of the first molded body; when stacking the second molded body on the first molded body, the second resin is supplied in a shape that covers the end of the interface along the end of the interface of the first molded body; and when welding is performed, the second molded body is welded to the first molded body within a range that sandwiches the end of the interface of the first molded body.

[0178] [Item 6] A manufacturing device (1) for manufacturing a resin product using a fused deposition modeling three-dimensional printer (3) that produces a molded body by supplying molten resin in a string-like form from a molding nozzle (11), wherein the three-dimensional printer comprises: a molding control unit (S100) configured to control the operation of the molding nozzle (11A) to supply a first resin that is laser-light-absorbent to produce a first molded body (71); and a lamination control unit (S110) configured to control the operation of the molding nozzle (11B) to supply a second resin that is laser-light-transmittable to a surface of the first molded body to produce a second molded body (81) to be laminated on the first molded body; and the manufacturing device comprises a laser device (5) having a laser irradiation unit (31) that irradiates laser light, and the laser device A resin product manufacturing device comprising a laser control unit (S120) configured to control the operation of the laser irradiation unit and irradiate the laser light along a path from the second molded body side, passing through an irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

[0179] [Item 7] A manufacturing apparatus (100) for manufacturing a resin product using a fused deposition modeling three-dimensional printer that produces a molded body by supplying molten resin in a string-like form from a shaping nozzle (11), the three-dimensional printer comprising: a molding device (101) having a molding control unit (S100) configured to control the operation of the shaping nozzle (11A) to supply a first resin having laser light absorbency to produce a first molded body (71); and a lamination device (103) having a lamination control unit (S110) configured to control the operation of the shaping nozzle (11B) to supply a second resin having laser light transmittance to a surface of the first molded body to produce a second molded body (81) to be laminated on the first molded body, the lamination device comprising a laser device (5) having a laser irradiation unit (31) that irradiates laser light, the laser device A resin product manufacturing device comprising a laser control unit (S120) configured to control the operation of the laser irradiation unit and irradiate the laser light along a path from the second molded body side, passing through an irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

[0180] [Item 8] The resin product manufacturing apparatus according to item 6 or 7, comprising a gas device (7) used when supplying the second resin to the surface of the first molded body, the gas device (7) spraying a pressing gas onto the supplied second resin so as to press the second resin toward the first molded body.

[0181] [Item 9] The resin product manufacturing apparatus according to any one of items 6 to 8, which is an apparatus used when welding the first molded body and the second molded body, and which includes a gas device that blows a pressing gas against the surface of the second molded body so as to press the second molded body against the first molded body side and / or so as to press the first molded body against the surface of the first molded body against the second molded body side.

[0182] [Item 10] An apparatus for manufacturing a resin product according to any one of items 6 to 9, wherein the first molded body has an interface where a plurality of string-like portions made of the first resin abut, and an end of the interface is exposed on a surface of the first molded body, the lamination control unit is configured to control the operation of the shaping nozzle when laminating the second molded body onto the first molded body, to supply the second resin in a shape that straddles the end of the interface of the first molded body, and the laser control unit is configured to control the operation of the laser irradiation unit, to weld the second molded body to the first molded body within a range that sandwiches the end of the interface of the first molded body.

[0183] [Item 11] An apparatus for manufacturing a resin product according to any one of items 6 to 9, wherein the first molded body has an interface where a plurality of string-like portions made of the first resin abut, and an end of the interface is exposed on a surface of the first molded body; the lamination control unit is configured to, when laminating the second molded body onto the first molded body, control the operation of the shaping nozzle to supply the second resin in a shape that covers the end of the interface along the end of the interface of the first molded body; and the laser control unit is configured, when welding the first molded body and the second molded body, to weld the second molded body to the first molded body within a range that sandwiches the end of the interface of the first molded body.

Claims

1. A manufacturing method for manufacturing a resin product using a fused deposition modeling three-dimensional printer (3) that supplies molten resin in a string-like form from a modeling nozzle (11) to produce a molded body, comprising the steps of: producing a first molded body (71) using a first resin that is laser light absorbent; supplying a second resin that is laser light transparent to the surface of the first molded body to produce a second molded body (81) so as to be laminated on the first molded body; and irradiating laser light along a path from the second molded body side, passing through an irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

2. A method for manufacturing a resin product as described in claim 1, wherein, when the second resin is supplied to the surface of the first molded body, a pressing gas is sprayed onto the supplied second resin so as to press the second resin towards the first molded body.

3. A method for manufacturing a resin product as described in claim 1 or claim 2, wherein, when welding the first molded body and the second molded body, a pressing gas is sprayed against the surface of the second molded body so as to press the second molded body against the first molded body and / or so as to press the first molded body against the surface of the first molded body against the second molded body.

4. A method for manufacturing a resin product as described in claim 1, wherein the first molded body has an interface where multiple string-like portions made of the first resin abut, and an end of the interface is exposed on the surface of the first molded body, and when the second molded body is laminated onto the first molded body, the second resin is supplied in a shape that spans the end of the interface of the first molded body, and when the welding is performed, the second molded body is welded to the first molded body within an area that sandwiches the end of the interface of the first molded body.

5. A method for manufacturing a resin product as described in claim 1, wherein the first molded body has an interface where multiple string-like portions made of the first resin abut, and an end of the interface is exposed on the surface of the first molded body, and when the second molded body is laminated onto the first molded body, the second resin is supplied in a shape that covers the end of the interface along the end of the interface of the first molded body, and when the welding is performed, the second molded body is welded to the first molded body within an area that sandwiches the end of the interface of the first molded body.

6. A manufacturing device (1) for manufacturing a resin product using a fused deposition modeling three-dimensional printer (3) that produces a molded body by supplying molten resin in a string-like form from a modeling nozzle (11), wherein the three-dimensional printer comprises: a molding control unit (S100) configured to control the operation of the modeling nozzle (11A) to supply a first resin having laser light absorbency to produce a first molded body (71); and a lamination control unit (S110) configured to control the operation of the modeling nozzle (11B) to supply a second resin having laser light transmittance to the surface of the first molded body to produce a second molded body (81) to be laminated on the first molded body; and the manufacturing device comprises a laser device (5) having a laser irradiation unit (31) that irradiates laser light, and the laser device: A resin product manufacturing apparatus comprising: a laser control unit (S120) configured to control the operation of the laser irradiation unit to irradiate the laser light along a path from the second molded body side, passing through an irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

7. A manufacturing apparatus (100) for manufacturing a resin product using a fused deposition modeling three-dimensional printer that produces a molded body by supplying molten resin in a string-like form from a modeling nozzle (11), comprising: a modeling apparatus (101) having a modeling control unit (S100) configured to control the operation of the modeling nozzle (11A) to supply a first resin having laser light absorbency to produce a first molded body (71); and a lamination apparatus (103) having a lamination control unit (S110) configured to control the operation of the modeling nozzle (11B) to supply a second resin having laser light transmittance to the surface of the first molded body to produce a second molded body (81) to be laminated on the first molded body, the lamination apparatus comprising a laser device (5) having a laser irradiation unit (31) that irradiates laser light, the laser device comprising: A resin product manufacturing apparatus comprising: a laser control unit (S120) configured to control the operation of the laser irradiation unit to irradiate the laser light along a path from the second molded body side, passing through an irradiation area between the first molded body and the second molded body, to the first molded body, thereby welding the first molded body and the second molded body.

8. An apparatus for manufacturing a resin product as described in claim 6 or claim 7, which is an apparatus used when supplying the second resin to the surface of the first molded body, and which includes a gas device (7) that blows a pressing gas against the supplied second resin so as to press the second resin toward the first molded body.

9. An apparatus for manufacturing a resin product as described in claim 6 or claim 7, which is an apparatus used when welding the first molded body and the second molded body, and which is equipped with a gas device that blows a pressing gas so as to press the second molded body against the surface of the second molded body toward the first molded body and / or so as to press the first molded body against the surface of the first molded body toward the second molded body.

10. An apparatus for manufacturing a resin product as described in claim 6 or claim 7, wherein the first molded body has an interface where multiple string-like portions made of the first resin abut, and an end of the interface is exposed on the surface of the first molded body, the lamination control unit is configured to control the operation of the shaping nozzle when laminating the second molded body onto the first molded body, to supply the second resin in a shape that spans the end of the interface of the first molded body, and the laser control unit is configured to control the operation of the laser irradiation unit to weld the second molded body to the first molded body within a range that sandwiches the end of the interface of the first molded body.

11. A resin product manufacturing apparatus as described in claim 6 or claim 7, wherein the first molded body has an interface where multiple string-like portions made of the first resin abut, and an end of the interface is exposed on the surface of the first molded body, the lamination control unit is configured to, when laminating the second molded body onto the first molded body, control the operation of the shaping nozzle to supply the second resin in a shape that covers the end of the interface along the end of the interface of the first molded body, and the laser control unit is configured to, when welding the first molded body and the second molded body, weld the second molded body to the first molded body within a range that sandwiches the end of the interface of the first molded body.

Images