Three-dimensional shaping device

Abstract

The present invention provides a three-dimensional shaping device that can control the solidification of a shaped object by means of a simple configuration. The present invention relates to a three-dimensional shaping device (1) that comprises a tool head (200) that melts a filament, a tool head movement mechanism (300) that moves the tool head (200), a build plate (500) that carries a shaped object that is formed by discharge from the tool head (200), a chamber (A) that accommodates at least the tool head (200) and the build plate (500), a chamber blower (600) that agitates the air in the chamber (A) and cools the shaped object, and a power supply (700) and a control device (800) for operating the abovementioned elements. The chamber blower (600) has an intake port (610) for bringing air into the chamber (A), a fan (620) for sucking in air through the intake port (610), a duct (630) that is a passage for air sucked in by the fan (620), and a blowing port (640) for discharging air from the duct (630) toward the shaped object. The fan (620) and the duct (630) are outside the chamber.

Description

3D molding equipment

[0001] The present invention relates to a three-dimensional forming apparatus.

[0002] In recent years, three-dimensional molding devices, so-called 3D printers, which can easily mold three-dimensional objects, have become increasingly popular. There are various types of three-dimensional molding devices, such as the fused deposition modeling method, which molds three-dimensional objects by melting and layering filaments of thermoplastic resin such as ABS resin at high temperature.

[0003] A three-dimensional molding device using the fused deposition modeling method typically includes a tool head that melts the filament, an XY mechanism that moves the tool head horizontally, a build plate on which the object to be molded by being ejected from the tool head is placed, a lifting mechanism that raises and lowers the build plate, a filament supply mechanism that supplies the filament to the tool head, and a control device that controls the operation of these components.

[0004] In fused deposition modeling, the high-temperature thermoplastic resin ejected from the tool head undergoes thermal contraction when it changes from a fluid state to a solid, causing thermal stress in the modeled product. While this thermal stress can be alleviated by modeling at a higher temperature, this can have a negative impact on the filament delivery and XY mechanism.

[0005] In contrast, the three-dimensional molding device described in Patent Document 1 addresses this issue by forming a molded object in a chamber equipped with a heater and installing an XY mechanism outside the chamber.

[0006] U.S. Patent No. 6,722,872

[0007] In recent years, there have been cases where shaping is performed using filaments that melt at extremely high temperatures, such as polyphenylene sulfide resin. In such cases, the temperature inside the chamber of a three-dimensional molding device such as that described in Patent Document 1 can become too high.

[0008] First Invention: If the temperature inside the chamber becomes too high, the object will be difficult to solidify during molding. Therefore, an object of the present invention is to provide a three-dimensional molding device that is simple in configuration and enables control of the solidification of the object.

[0009] <Second Invention> An object of the present invention is to provide a three-dimensional molding device that allows temperature control inside a chamber with a simple configuration.

[0010] <<Third Invention>> When the temperature inside the chamber becomes too high, the build plate of a three-dimensional molding device is affected by thermal expansion, which can cause distortion in the fixing parts, etc., resulting in device failure or making it impossible to maintain the horizontality of the build plate. Therefore, an object of the present invention is to provide a build plate with a simple configuration that is less affected by thermal expansion of the build plate during molding and / or that can easily achieve high horizontality, a three-dimensional molding device equipped with the same, and a three-dimensional molding method using the same.

[0011] <<First Invention>> As a first embodiment of the first invention, a three-dimensional molding apparatus includes a tool head that melts a filament, a tool head moving mechanism that moves the tool head, a build plate on which a modeled object ejected from the tool head is placed, a chamber that stores at least the tool head and the build plate, a chamber blower that agitates the air in the chamber and cools the model, and a power source and a control device for operating these components, wherein the chamber blower has an air intake port that takes in air from the chamber, a fan that draws air through the air intake port, a duct that is a flow path for the air drawn in by the fan, and an air outlet that sends the air from the duct to the model, and the fan and duct are located outside the chamber.

[0012] <<Second Invention>> As a first embodiment of the second invention, a three-dimensional molding device includes a tool head that melts a filament, a tool head mechanism that moves the tool head, a build plate on which a modeled object ejected from the tool head is placed, a chamber that stores at least the tool head and the build plate, a first fan that cools the chamber, a housing having a first opening that can take in outside air and a second opening that can exhaust internal air, and a power source and a control device for operating these components, and the fan introduces the outside air taken in through the first opening into the chamber.

[0013] <<Third Invention>> As a first embodiment of the third invention, the build plate of the third invention relates to a build plate having an upper plate and a lower plate, wherein the upper plate is fixed in a slidable state relative to the lower plate, and the lower plate is divided into at least a first part and a second part, each of which can be raised and lowered by a lifting mechanism.

[0014] The present invention can provide a three-dimensional molding device that allows for control of solidification of a molded object or temperature control with a simple configuration.The present invention also provides a build plate that is less susceptible to thermal expansion during molding and / or that can easily achieve high levelness, and a three-dimensional molding device equipped with the same.

[0015] FIG. 1A is a front perspective view of one embodiment of a three-dimensional forming apparatus, as viewed from an obliquely upward direction. FIG. 1B is a rear perspective view of one embodiment of a three-dimensional forming apparatus, as viewed from an obliquely downward direction. FIG. 2 is a perspective view of the three-dimensional forming apparatus without the housing, showing the interior of the three-dimensional forming apparatus. FIG. 3 is a side cross-sectional view of the three-dimensional forming apparatus, showing each region within the three-dimensional forming apparatus. FIG. 4 is a perspective view of the three-dimensional forming apparatus without the housing and chamber walls, showing the configuration of one embodiment of an XY mechanism in detail. FIG. 5 shows the configuration of one embodiment of an X bar and pulleys attached to a Y bar, which is a linear guide, in the XY mechanism of the three-dimensional forming apparatus. FIG. 6 is a schematic diagram of the three-dimensional forming apparatus of FIG. 1, excluding the housing and other components. FIG. 7A is a schematic plan view of one embodiment of a build plate. FIG. 7B is a schematic side view of one embodiment of a build plate. FIG. 8A is a schematic perspective view of the fixing portion between the upper plate and the lower plate in one embodiment of a build plate. FIG. 8B shows a schematic cross-sectional view of the fastening portion between the upper plate and the lower plate for one embodiment of a build plate. FIG. 8C shows a schematic cross-sectional view of the fastening portion when the upper plate is tilted relative to the lower plate for one embodiment of a build plate. FIG. 9A shows a schematic perspective view of another embodiment of the fastening portion between the upper plate and the lower plate. FIG. 9B shows a schematic cross-sectional view of another embodiment of the fastening portion between the upper plate and the lower plate. FIG. 10 is a perspective view of the three-dimensional molding apparatus from the rear obliquely above, without the housing and chamber walls, showing in detail the configuration of one embodiment of the power supply and other components outside the chamber. FIG. 11A is a perspective cross-sectional view of one embodiment of a three-dimensional molding apparatus, showing in detail the duct of the chamber blower. FIG. 11B is a front view of one embodiment of a three-dimensional molding apparatus, showing in detail the fan and exhaust port of the chamber blower.

[0016] The present invention will be specifically described using the following embodiments as examples, but the present invention is not limited thereto. Unless specifically mentioned in this specification in detail for each device, mechanism, means, manufacturing method, etc., those skilled in the art can use mechanical devices, mechanisms, means, manufacturing methods, etc. that are well known to those skilled in the art. Each embodiment can be combined based on ordinary knowledge by those skilled in the art, and configurations not specifically mentioned in each embodiment can have the same configuration as other embodiments or a configuration appropriate for that embodiment.

[0017] In this specification, "top" or "upper side" refers to the positive direction of the Z axis in the drawings, and "bottom" or "lower side" refers to the negative direction of the Z axis. "Inside" refers to being closer to the center position of the three-dimensional molding device, and "outside" refers to being farther from the center position of the three-dimensional molding device. "Inside" refers to being located inside the housing of the three-dimensional molding device, and "outside" refers to being located outside the housing of the three-dimensional molding device.

[0018] Figure 1A is a front perspective view of one embodiment of a three-dimensional forming apparatus, as seen from an obliquely upward direction. Figure 1B is a rear perspective view of one embodiment of a three-dimensional forming apparatus, as seen from an obliquely downward direction. Figure 2 is a perspective view of the three-dimensional forming apparatus of Figure 1A without the housing, showing the interior of the three-dimensional forming apparatus. Figure 3 is a side cross-sectional view of the three-dimensional forming apparatus, showing each region within the three-dimensional forming apparatus.

[0019] 1A and 1B, the three-dimensional molding device 1 has a housing 100 consisting of an upper surface 10, a lower surface 20, a front surface 30, a rear surface 40, a right side surface 50, and a left side surface 60. The front surface 30 has a door and a handle 31 for removing the molded object after molding. The upper surface 10 can also be easily opened for the purpose of attaching a filament to a tool head 200, for example.

[0020] In the three-dimensional molding device 1, for example, a filament roll can be attached to the outside of the housing 100, for example, on the right side surface 50, left side surface 60, etc., and filament can be supplied from the filament roll to the extruder of the tool head 200 through an opening or the like in the housing 100. In this specification, these well-known configurations are omitted because they are not related to the features of the present invention.

[0021] 2, the three-dimensional molding device 1 includes a chamber A surrounded by an inner wall different from the outer wall of the housing. In this embodiment, the chamber A is surrounded by a rear inner wall 40a, a right inner wall 50a, and a left inner wall 60a. The chamber A houses the discharge portion of the tool head 200 and the build plate 500, and three-dimensional molding is performed within the chamber A.

[0022] 3, the three-dimensional molding device 1 has a chamber A, an electrical equipment space B, and an upper space C. The upper part of the chamber A is defined by an XY plate 400, and the lower part is defined by the lower surface 20 of the housing.

[0023] In this embodiment, the electrical equipment space B is located between the rear inner wall 40a of the chamber A and the rear surface 40 of the housing. The upper portion of the electrical equipment space B is also defined by the XY plate 400, and the lower portion is defined by the bottom surface 20 of the housing. At least one of the power supply 700 and the control device 800 is disposed in the electrical equipment space B. However, the location of the electrical equipment space B is not particularly limited as long as it is outside the chamber A. For example, if the housing does not have a rear surface 40, the electrical equipment space B may be a space exposed to the outside, or may be located outside the bottom surface 20 of the housing.

[0024] An upper space C exists above the chamber A. The upper space C is an area located above the XY plate 400, and the XY mechanism 300 exists therein.

[0025] Although not shown, a right space and a left space also exist between the right inner wall 50a of chamber A and the right side surface 50 of the housing 100, and between the left inner wall 60a of chamber A and the left side surface 60 of the housing 100, respectively. Either the power supply 700 or the control device 800 may be located in the right space or the left space. Furthermore, the chamber blower 600 may be located in the right space or the left space.

[0026] In this embodiment, the presence of an inner wall that constitutes chamber A provides high thermal insulation to chamber A. Furthermore, because the space of the modeling area where three-dimensional modeling is performed is limited, the temperature inside chamber A increases even when a small amount of heat is applied. This configuration allows the power sources for the heat sources inside chamber A, such as the heater for the build plate 500 and the PTC heater for heating the inside of chamber A, to be miniaturized.

[0027] On the other hand, chamber A has no inner wall on the front side (i.e., the positive side of the Y axis), and the front side is defined by the front surface 30 of the housing 100. In addition, chamber A also has no inner wall on the upper part, and the upper part is substantially open except for the region where the XY plate 400 is present, so that airflow can flow between chamber A and the upper space C without impeding the movement of the tool head 200 in the X and Y directions.

[0028] 1A , the right side surface 50 of the housing 100 has a first opening 51 for introducing outside air F1 into the three-dimensional molding apparatus 1 and into the chamber A. However, the location of the first opening for introducing outside air F1 is not particularly limited as long as it can introduce outside air F1 so as to adjust the temperature inside the chamber A, and it may be located on the top surface 10, bottom surface 20, front surface 30, back surface 40, and / or left side surface 60 of the housing 100. Furthermore, the first opening 51 for introducing outside air F1 may be located in multiple locations.

[0029] 2, in this embodiment, a first fan 52 is located inside the first opening 51 of the housing 100 in the upper space C of the three-dimensional forming apparatus 1. This first fan 52 can draw in outside air F1 through the first opening 51. In this manner, the first opening 51 and the first fan 52 may be located close to each other. Here, "close to each other" means that the distance between their respective center positions is within about 20 cm, about 15 cm, about 10 cm, about 8 cm, or about 5 cm.

[0030] 1B , the underside 20 of the housing 100 has a second opening 21 through which the internal air F2 can be discharged. For example, the first fan 52 may be located in proximity to the second opening 21, and no fan may be present in proximity to the first opening 51. When the first fan 52 is located in proximity to the second opening 21 and discharges the internal air F2 through the second opening 21, the inside of the three-dimensional forming apparatus 1 becomes negative pressure, and therefore the outside air F1 is sucked in through the first opening 51 and introduced into the chamber A.

[0031] The rear surface 40 of the housing 100 has third openings 41 and 42. The third openings 41 and 42 are vents for introducing outside air into the electrical equipment space B, and a second fan can be provided in the electrical equipment space B in accordance with the position of these openings. This allows the power supply 700, control device 800, etc. in the electrical equipment space B to be cooled, thereby lowering the temperature within the electrical equipment space B. The rear surface 40 of the housing 100 can also have an opening that allows the air inside the electrical equipment space B to be exhausted.

[0032] Figure 4 is an oblique view of the three-dimensional molding device 1 without showing the wall surface of chamber A, and shows in detail the configuration of the tool head 200, XY mechanism 300, XY plate 400 to which the XY mechanism 300 is attached, build plate 500, etc.

[0033] The three-dimensional molding device 1 is a fused deposition modeling device. This method forms a model on a build plate 500 by melting a thermoplastic resin filament, which serves as the modeling material, with a tool head 200. The tool head 200 moves horizontally to dispense molten resin onto the build plate 500, while the build plate 500 moves vertically using an elevating mechanism 530, thereby forming a three-dimensional model.

[0034] The tool head 200 can move in the horizontal direction. As the system of the XY mechanism 300, for example, an open source operation system called the CoreXY system can be adopted. However, the XY mechanism 300 is not limited to this as long as it can move the tool head 200 in the horizontal direction, and other systems such as a Cartesian system, a cross-gantry system, or an H-bot system may also be adopted.

[0035] In this three-dimensional forming device 1, the XY mechanism 300 is substantially entirely disposed on the XY plate 400. By employing the highly rigid XY plate 400 and disposing the XY mechanism 300 on it, the XY mechanism 300 can move stably at high speed.

[0036] 3 , the XY plate 400 is located above the chamber A and below the upper space C, thereby defining the chamber A and the upper space C. The XY plate 400 is also located outside the chamber A in the horizontal direction; for example, the XY plate 400 can be located or extend between the upper inner wall of the chamber A and each surface of the housing 100.

[0037] 4 shows an embodiment in which the XY mechanism is a CoreXY system. In this system, two belts 301 and 302 are connected to the tool head 200 to drive the tool head 200 on the XY plane. By driving the two belts 301 and 302 with two motors 351 and 352, the tool head 200 can be freely moved via the X bar 310 and two Y bars 321 and 322.

[0038] In this XY mechanism, it is important to maintain the same tension in the two belts 301 and 302, and so the XY mechanism also has belt tensioners 341 and 342 corresponding to the two belts 301 and 302. The XY mechanism also has pulleys 331 and 332 that change the belt from the Y direction on the Y bar to the X direction on the X bar, and there are other pulleys in various locations.

[0039] In this embodiment, the influence of vibration is reduced by fixing two Y bars 321 and 322 on an XY plate 400. One X bar 310 is connected to the tool head 200 and is attached across the two Y bars 321 and 322 at both ends of the X bar 310.

[0040] 5, the Y bar 321 can be configured as a linear guide having rails 321a and blocks 321b, and the X bar 310 can be fixedly attached to the block 321b of the Y bar 321. Pulleys 331a and 331b for two belts (not shown) are further attached to the block 321b of the Y bar 321. In such an embodiment, an XY mechanism can be configured very simply and lightly, which enables the tool head 200 to move horizontally at high speed.

[0041] 6, 7A, and 7B, the build plate 500 has an upper plate 510 and a first portion 520a and a second portion 520b of a lower plate. The lifting mechanism 530 is not directly connected to the upper plate 510, but is connected to the lower plate 520. The lower surface 20 of the housing 100 is also shown below the lower plate 520.

[0042] The upper plate 510 is a plate on which an object is molded. The upper plate 510 may have, for example, a sheet-shaped heater on the same surface, behind the surface on which the object is molded. However, the heater does not have to be located on the back side of the upper plate 510, and it does not have to be sheet-shaped. The heater may be a heater that heats the entire interior of chamber A. When the build plate 500 on which the object is placed is heated, heat is more easily transferred to the object than when the entire interior of chamber A is heated, and thermal stress generated in the object can be minimized.

[0043] The upper plate 510 can be a single plate-like member that is not divided in the XY plane, but may be divided into two or more parts in the XY plane as long as an advantageous effect is obtained.

[0044] The upper plate 510 is fixed to the lower plate 520 in a slidable state, and therefore can freely expand and contract by sliding even if it expands when heated. Note that by molding the object from the center of the upper plate 510, it is possible to prevent the thermal expansion of the upper plate 510 from substantially affecting the dimensional accuracy of the object.

[0045] In this embodiment, the lower plate 520 is divided into at least a first portion 520a and a second portion 520b, but may be divided into three or more portions. When the lower plate 520 is divided into three or more portions, each of the portions may be connected to a lifting mechanism.

[0046] Depending on the aspect ratio of the build plate 500, the lower plate 520 is preferably divided into two parts in the depth direction of the three-dimensional forming apparatus 1, i.e., in the Y direction. This allows the levelness of the upper plate 510 to be adjusted in the Y-Z directions. For example, in a conventional three-dimensional forming apparatus 1 in which a single lifting mechanism 530 is located on the depth side, the levelness in the X-Z directions has been addressed by various means, but the levelness in the Y-Z directions has not been substantially considered. When using a lower plate 520 divided into two parts in the Y direction, the levelness in the Y-Z directions can be adjusted, which can address, for example, cases in which the plate bends due to a heavy object being formed, or cases in which the levelness in the Y-Z directions cannot be maintained due to some kind of impact. However, the lower plate 520 may also be divided into two parts in the width direction of the three-dimensional forming apparatus 1, i.e., in the X direction, thereby allowing the levelness in the X-Z directions to be adjusted.

[0047] 6 , the first portion 520a of the lower plate 520 spans substantially the entire width of the build plate 500 in the X direction. The second portion 520b is separated from the first portion 520a in the Y direction and has only a width sufficient to connect to a lifting mechanism in the X direction and to support the upper plate 510. The first portion 520a and the second portion 520b of the lower plate 520 each extend outside the upper plate 510 in the X-Y plane and can connect to lifting mechanisms 530a, 530b, and 530c at portions outside the upper plate 510.

[0048] The first portion 520a of the lower plate 520 can be raised and lowered by two lifting mechanisms 530a, 530b at both ends in the X direction. In this embodiment, the two lifting mechanisms of the first portion 520a can adjust the position of the entire build plate 500 in the Z direction and the levelness in the X-Z directions. Furthermore, the lifting mechanism 530c to which the second portion 520b of the lower plate 520 is connected can adjust the position of the entire build plate 500 in the Z direction and the levelness in the Y-Z directions. This allows the levelness of the upper plate 510 to be completely controlled regardless of the position of the build plate 500 on the Z axis. However, the first portion 520a of the lower plate 520 may be connected to a single lifting mechanism as long as it can maintain the levelness in the X-Z directions.

[0049] As shown in FIG. 7B, the lifting mechanism 530 can be composed of a sliding screw 531, a linear bushing 532, and a motor 533 for the sliding screw 531.

[0050] The lifting mechanism 530 for the second portion 520b of the lower plate 520 has two linear bushings 532, 532'. By configuring the lifting mechanism 530 in this manner, the lower plate 520 can be raised and lowered in the Z-axis direction without being subjected to a rotational force. The sliding screw 531 is connected at its lower part to a motor 533 located below the lower surface 20 of the housing 100, as shown in FIG. 1B . However, the upper part of the sliding screw 531 is not connected to any other member. In contrast, the linear bushing 532 is connected at its lower part to the lower surface 20 of the housing 100, and can be connected at its upper part to a drive mechanism of the tool head 200, etc.

[0051] The size of the upper plate 510 is 100 cm ２ Above, 300cm ２ Above, 500cm ２ Above, 800cm ２ or more, or 1000 cm ２ or more, 10,000 cm ２ Below, 5000cm ２ or less than 3000 cm ２The aspect ratio (X dimension:Y dimension) of the top plate may be in the range of 1:0.1 to 1:10, 1:0.3 to 1:3, or 1:0.5 to 1:2.

[0052] The fixing portion 501 of the upper plate 510 relative to the lower plate 520 is not limited as long as it is slidable. For example, as shown in FIG. 7A , the upper plate 510 can be fixed with bolts and nuts in elongated holes extending in the direction of thermal expansion, or can be fixed using linear guides, slide rails, or the like. In this case, the elongated holes may be in either the upper plate 510 or the lower plate 520. Furthermore, the upper plate 510 and the lower plate 520 can be fixed in a slidable state by interposing an elastic body such as a spring between them. In this case, even if some external force is applied to the upper plate, the upper plate 510 will simply tilt, and the upper plate 510 will be less likely to be damaged.

[0053] In the embodiment shown in Figures 6 and 7A, a first portion 520a of the lower plate 520 is fixed to the upper plate by two fixing portions 501a and 501b, and a second portion 520b of the lower plate 520 is fixed to the upper plate by one fixing portion 501c.

[0054] Fig. 8A shows a perspective view of a fixed portion 501a between an upper plate 510 and a first portion 520a of a lower plate 520. Fig. 8B shows a cross-sectional view of the fixed portion 501a in Fig. 8A. In this embodiment, the fixed portion 501a is fixed by the upper plate 510 contacting the first portion 520a of the lower plate via a spherical member 502.

[0055] As shown in FIG. 8B , the bolt 503 of the fixed portion 501a passes through the spherical member 502, two washers 504, 504′, and the elastic member 505 and is secured with a nut 506. Here, the elastic member 505 is made of a flexible material such as silicone rubber, and the presence of the elastic member 505 allows the upper plate 510 and the first portion 520a of the lower plate to be tightly constrained while being pressed together. The elastic member 505 is not limited to a flexible material as long as it can constrain the two plates while being pressed together, and may be, for example, a compression spring. By securing the plates via the spherical member in this manner, the upper plate 510, the spherical member 502, and the lower plate 520 are in point contact with each other, thereby minimizing heat transfer from the upper plate 510 to the lower plate 520.

[0056] 8C , the upper plate 510, the spherical member 502, and the lower plate 520 are in point contact with each other, allowing the upper plate 510 to tilt slightly. Therefore, even if an external force is applied to the upper plate 510, the upper plate 510 only tilts, and the upper plate 510 is less likely to be damaged. Even if the upper plate 510 tilts, the build plate 500 can be fully automatically calibrated to be horizontal when incorporated into the three-dimensional molding device 1, and performing this calibration allows for three-dimensional molding without any problems.

[0057] In this way, the spherical member 502 is very useful for fastening two plates together, and this fastening method is useful in a variety of applications for fastening two plates together, not just for fastening the upper plate 510 and the lower plate 520 together.

[0058] Fig. 9A shows a perspective view of another embodiment of a fixed portion 501a between an upper plate 510 and a first portion 520a of a lower plate 520. Fig. 9B shows a cross-sectional view of the fixed portion 501a of Fig. 9A. In this embodiment, a round-head bolt 503, which is a spherical member 502, allows the upper plate 510 to slide relative to the first portion 520a of the lower plate.

[0059] In this embodiment, spacers 507 are provided on the outside of the round head bolts 502 and 503 to define the distance between the upper plate 510 and the first portion 520a of the lower plate 520. The mere presence of the round head bolts 502 and 503 does not secure the upper plate 510 and the first portion 520a of the lower plate 520 together, so the upper plate 510 and the lower plate 520 are secured together by connecting them via a spring 508, which is an elastic body.

[0060] In this embodiment, the fixation by the spring 508 can restrain the upper plate 510 and the first portion 520a of the lower plate while pressing them together, and the round-head bolts 502 and 503 allow them to slide. The spring 508 is attached between the attachment bolt 510x attached to the side surface of the upper plate 510 and the attachment hole 520x in the first portion 520a of the lower plate 520, but there is no particular limitation on how the spring 508 is attached.

[0061] The tool head 200 may have a touch-type leveling sensor known in the art as a levelness measurement mechanism. The levelness of the upper plate 510 can be measured by scanning the tool head 200 over the upper plate 510 and measuring the distance from the tool head 200 in the Z direction at, for example, three positions. Various types of levelness measurement mechanism can be used, such as an electromagnetic induction sensor, a Time of Flight optical sensor, a LiDAR sensor, an electrical current sensor, or an inclination sensor.

[0062] Before starting modeling, the three-dimensional molding apparatus 1 measures the level of the build plate 500 using a level measurement mechanism, and the control device 800 can adjust the level of the build plate 500 using the lifting mechanism 530 based on the level information. This level adjustment process can be repeated two or more times until the level is within an acceptable range. Once the build plate 500 is level, a modeling material such as a filament is provided to the tool head 200, and the tool head 200 forms a model.

[0063] Various settings of the three-dimensional forming apparatus 1 are configured using a control panel attached to the housing or through a terminal connected by wire or wirelessly to the control device 800. The control device 800 can control the operation of the build plate 500 and the lifting mechanism 530 by controlling motors and the like, and can also control the temperature of the build plate 500 and the tool head 200 by controlling heaters and the like.

[0064] Figure 10 is a perspective view of the three-dimensional molding device 1 viewed from diagonally above the rear, without showing the wall surfaces of the housing 100 and chamber A, and shows in detail the configuration of one embodiment of the chamber blower 600, power supply 700, control device 800, etc. in the electrical equipment space B.

[0065] A power supply 700 provides power to the various elements, and a control device 800 controls the operation of the various elements. For example, the control device 800 can control the temperature in chamber A within a set range by controlling the operation of the first fan 52 using PID control or the like based on a signal from a temperature sensor in chamber A.

[0066] 10, the main body of the motors 351 and 352 for the XY mechanism 300 can be disposed in the electrical equipment space B, and only the driving parts of the motors can be disposed in the upper space C. This allows the motors 351 and 352 to be spatially isolated from the chamber A where three-dimensional molding is performed.

[0067] The temperature in the electrical equipment space B can be kept low by a second fan, such as the power supply fan 710 of the power supply 700 or the control device fan 810 of the control device 800. These second fans can be located inside the third openings 41 and 42 on the rear surface 40 of the three-dimensional molding apparatus 1 shown in FIG. 1B. In this embodiment, the motors are located outside of the chamber A, which becomes hot inside, preventing the motors of the XY mechanism from overheating. This allows the motors to be operated with a heavy load, enabling high-speed horizontal movement of the tool head 200. Furthermore, because a relatively high temperature inside the chamber A is less likely to adversely affect the motors 351 and 352 of the XY mechanism 300, this configuration is advantageous when using filaments that melt at relatively high temperatures.

[0068] However, in order to obtain the advantageous effects described above, the motors 351, 352 do not have to be limited to such positions as long as they are spatially isolated from the interior of the chamber A. For example, the motors 351, 352 may be arranged in the upper space C, spatially isolated from the chamber A and the upper space C by a motor cover or the like, and exposed to the outside air through an opening in the housing 100. This allows the motors 351, 352 to be cooled by the outside air.

[0069] 10 , 11A, and 11B , in this embodiment, only the air intake 610 and the air outlet 640 of the chamber blower 600 face the chamber A, and the fan 620 body and the duct 630 are located within the electrical equipment space B. In this embodiment, the air intake 610 is also the air intake of the fan 620, but the configurations of the air intake 610 and the fan 620 are not particularly limited as long as they can take in air from the chamber A.

[0070] As in this embodiment, the fan 620 of the chamber blower 600 is located at the bottom of the chamber A, and by operating the fan 620, air can be drawn into the chamber A through the air intake 610. The drawn air passes through a duct 630 and is exhausted from an air outlet 640 located at the top of the chamber A. The air outlet 640 can send air toward the vicinity of the nozzle of the tool head 200. Furthermore, as shown in FIG. 11B , the air outlet 640 can exhaust air across the entire width of the build plate 500 in the X direction.

[0071] The chamber blower 600 can circulate air within chamber A, thereby effectively cooling the object. The object on the build plate 500 may be hot, at around 100°C. If air at a temperature close to the outside air temperature is blown directly onto the object, the object may be cooled suddenly, causing cracks or other problems. However, blowing air from within chamber A using the chamber blower 600 is preferable because it does not cause sudden cooling.

[0072] The fan 620 and duct 630 of the chamber blower 600 are located in the electrical equipment space B, which is maintained at a relatively low temperature, allowing a fan with low heat resistance to be used. Furthermore, when the fan 620 and duct 630 are located in the electrical equipment space B, the configuration inside the chamber A can be simplified. This improves the design quality inside the chamber A and increases the degree of freedom in the design of the build plate 500 and its lifting mechanism 530.

[0073] For example, a VOC filter may be disposed in the duct 630 of the chamber blower 600 to remove volatile organic compounds (VOCs) generated when melting the filaments in the chamber A.

[0074] Any type of VOC filter may be used as long as it can remove VOCs, and may be, for example, a filter using a porous adsorbent material such as activated carbon or zeolite.

[0075] The location of the VOC filter is not particularly limited as long as it can remove VOCs generated within chamber A. For example, the configuration may be such that air passing through the second opening 21 for discharging internal air also necessarily passes through the VOC filter.

[0076] The present invention can have the following aspects.

[0077] <<First Invention>> As a first embodiment of the first invention, a three-dimensional molding apparatus includes a tool head that melts a filament, a tool head moving mechanism that moves the tool head, a build plate on which a modeled object ejected from the tool head is placed, a chamber that stores at least the tool head and the build plate, a chamber blower that agitates the air in the chamber and cools the model, and a power source and a control device for operating these components, wherein the chamber blower has an air intake port that takes in air from the chamber, a fan that draws air through the air intake port, a duct that is a flow path for the air drawn in by the fan, and an air outlet that sends the air from the duct to the model, and the fan and duct are located outside the chamber.

[0078] If the temperature inside the chamber becomes too high, the object will not solidify during modeling. However, in the present invention, the use of a chamber blower allows for effective cooling of the object. The object on the build plate may be hot, around 100°C, and if air at a temperature close to the outside air temperature is blown directly onto the object, the object will cool rapidly, potentially causing cracks or other damage. However, it has been found that if the heated air inside the chamber is blown onto the object using a chamber blower, the object will not cool rapidly, making it less likely to crack.

[0079] Furthermore, if the chamber blower fan is located outside the chamber, a fan with low heat resistance can be used. This configuration is advantageous because, in addition to the fan material, the driver circuitry attached to the fan requires high heat resistance when located inside the chamber. That is, a fan with high heat resistance is not only expensive, but also requires a coupling or belt between the motor and the fan, which increases the size and makes it unsuitable for miniaturizing a three-dimensional molding device. Furthermore, if the duct is located outside the chamber, the configuration inside the chamber can be simplified. This improves the design of the chamber and increases the design freedom of the build plate and its lifting mechanism.

[0080] As a second embodiment of the first aspect of the present invention, in the three-dimensional forming apparatus, the fan and duct of the chamber blower are located in the electrical equipment space in which the power supply and / or the control device are present.

[0081] The embodiment in which the chamber blower fan and duct are located in the electrical compartment is advantageous because the electrical compartment is maintained at a relatively low temperature.

[0082] As a third embodiment of the first aspect of the invention, a fan is provided for introducing outside air to cool the power supply and / or control device, and the power supply, control device, and motor of the XY mechanism are located in the electrical equipment space.

[0083] When the power supply and control device are cooled by a cooling fan, the electrical equipment space is kept at a low temperature. This configuration is advantageous because the motor of the XY mechanism can overheat when the tool head is moved at high speed and a high load is applied, and it is less likely to malfunction if it is located at a relatively low temperature.

[0084] As a fifth embodiment of the first invention, the three-dimensional molding device is such that the tool head moving mechanism is an XY mechanism that moves the tool head horizontally, and further includes a lifting mechanism that raises and lowers the build plate.

[0085] In this embodiment, it becomes easier to direct the air blown from the chamber blower onto the model.

[0086] As a fifth embodiment of the first invention, the three-dimensional molding apparatus further includes an XY plate for arranging the XY mechanism, the XY plate being positioned outside the top of the chamber, and the top of the chamber being substantially open.

[0087] In this embodiment, the thermal effect on the XY mechanism due to the temperature inside the chamber is minimized, the movement of the XY mechanism is not hindered, and it is possible to easily introduce outside air into the chamber using a fan.

[0088] As a sixth embodiment of the first invention, a three-dimensional molding device has a heater attached to the build plate, and the build plate has an upper plate and a lower plate, the upper plate is fixed in a slidable state relative to the lower plate, and the lower plate is divided into at least a first part and a second part, each of which can be raised and lowered by a lifting mechanism.

[0089] In this embodiment, even in a situation where the build plate is prone to high temperatures, the build plate is less susceptible to thermal expansion during molding, and / or high horizontality can be easily achieved. By having this configuration in a three-dimensional molding device that allows temperature control inside the chamber, it is possible to obtain three-dimensional molded products with high molding precision.

[0090] As a seventh embodiment of the first aspect of the present invention, the three-dimensional molding device has a VOC filter for removing VOCs from within the chamber.

[0091] In this embodiment, the use of a VOC filter to remove VOCs in the chamber is advantageous because it can prevent odor generation.

[0092] Second Invention As a first embodiment of the second invention, a three-dimensional molding device includes a tool head that melts a filament, a tool head moving mechanism that moves the tool head, a build plate on which a molded object ejected from the tool head is placed, a chamber that stores at least the tool head and the build plate, a first fan that cools the chamber, a housing having a first opening that can take in outside air and a second opening that can exhaust internal air, and a power source and a control device for operating these components, and the fan introduces the outside air taken in through the first opening into the chamber.

[0093] The use of a chamber allows for the heater used to heat the modeling area to be smaller, and the power supply for this can also be made smaller, which is advantageous for miniaturizing the three-dimensional molding device. However, the use of a chamber can sometimes cause the temperature inside the chamber to become too high, especially when using filaments that melt at high temperatures. In this embodiment, the temperature inside the chamber can be controlled very quickly and easily by introducing outside air into the chamber.

[0094] Furthermore, when modeling with a three-dimensional molding device, the lower layer must be solidified to a certain extent before printing the upper layer. On the other hand, in order to obtain a strong object, adhesion between the upper and lower layers is important, so even if the lower layer is too solidified, this can be problematic. Therefore, in order to obtain a strong object through high-speed modeling, it is necessary to precisely control the temperature inside the chamber depending on the modeling material. In this embodiment, the temperature inside the chamber can be controlled very precisely and easily by introducing outside air into the chamber.

[0095] As a second embodiment of the second invention, the three-dimensional molding device is further provided with an XY mechanism for moving the tool head horizontally, and an elevation mechanism for raising and lowering the build plate.

[0096] As a third embodiment of the second invention, the three-dimensional molding apparatus further includes an XY plate for arranging the XY mechanism, the XY plate being positioned outside the top of the chamber, and the top of the chamber being substantially open.

[0097] In this embodiment, the thermal effect on the XY mechanism due to the temperature inside the chamber is minimized, the movement of the XY mechanism is not hindered, and it is possible to easily introduce outside air into the chamber using a fan.

[0098] As a fourth embodiment of the second invention, a three-dimensional molding device has a heater attached to the build plate, and the build plate has an upper plate and a lower plate, the upper plate is fixed in a slidable state relative to the lower plate, and the lower plate is divided into at least a first part and a second part, each of which can be raised and lowered by a lifting mechanism.

[0099] In this embodiment, even in a situation where the build plate is prone to high temperatures, the build plate is less susceptible to thermal expansion during molding, and / or high horizontality can be easily achieved. By having this configuration in a three-dimensional molding device that allows temperature control inside the chamber, it is possible to obtain three-dimensional molded products with high molding precision.

[0100] As a fifth embodiment of the second aspect of the present invention, the three-dimensional molding apparatus has a chamber blower that agitates the air in the chamber and cools the molded object.

[0101] This embodiment allows for effective cooling of the object. The object on the build plate may be hot, around 100°C. If air at a temperature close to the ambient temperature is blown directly onto the object, the object will cool rapidly, potentially causing cracks. However, it has been found that if heated air from inside the chamber is blown onto the object using a chamber blower, the object will not cool rapidly, making it less likely to crack.

[0102] As a sixth embodiment of the second aspect of the present invention, in the three-dimensional forming apparatus, the fan and duct of the chamber blower are located outside the chamber.

[0103] If the chamber blower fan is located outside the chamber, a fan with low heat resistance can be used. This configuration is advantageous because, in addition to the fan material, the driver circuit associated with the fan requires high heat resistance when located inside the chamber. That is, a fan with high heat resistance is not only expensive, but also requires a coupling or belt between the motor and the fan, which increases the size and makes it unsuitable for miniaturizing three-dimensional molding devices. Furthermore, if the duct is located outside the chamber, the configuration inside the chamber can be simplified. This improves the design of the chamber and increases the design freedom of the build plate and its lifting mechanism.

[0104] As a seventh embodiment of the second invention, the three-dimensional molding device has a second fan for introducing outside air to cool the power supply and / or control device, and the power supply, the control device, the motor of the XY mechanism, and the fan and duct of the chamber blower are located in an electrical equipment space outside the chamber.

[0105] The power supply and control device are cooled by a cooling fan, and the space they are in is kept at a relatively low temperature. This configuration is advantageous because the motor of the XY mechanism can overheat when the tool head is moved at high speed and a high load is applied, and therefore failures are less likely to occur if it is located at a relatively low temperature.

[0106] As an eighth embodiment of the second aspect of the present invention, the three-dimensional molding device has a VOC filter for removing VOCs from within the chamber.

[0107] In a normal three-dimensional molding machine that does not introduce outside air, the odor generated is not a problem, but in a three-dimensional molding machine that introduces outside air into the chamber and exhausts the internal air, it was found that a strong odor caused by VOCs (volatile organic compounds) is generated. In contrast, it was found that the generation of odor can be prevented by using a VOC filter to remove VOCs from the chamber.

[0108] <<Third Invention>> As a first embodiment of the third invention, the build plate of the third invention relates to a build plate having an upper plate and a lower plate, wherein the upper plate is fixed in a slidable state relative to the lower plate, and the lower plate is divided into at least a first part and a second part, each of which can be raised and lowered by a lifting mechanism.

[0109] When the build plate becomes hot, it is affected by thermal expansion. However, in the present invention, because the upper plate is fixed in a slidable state relative to the lower plate, thermal expansion of the upper plate does not adversely affect other components. Furthermore, if the build plate is fixed at one point like a cantilever, the build plate may bend when a heavy object is molded on the build plate. This can cause the build plate to become unable to maintain its horizontality. However, in the present invention, because the lower plate is divided into at least a first portion and a second portion and supports the upper plate from below, the build plate is less likely to bend. Furthermore, because the lower plate is divided into at least a first portion and a second portion, even if heat is transferred to the lower plate, thermal expansion of the lower plate does not significantly affect other components.

[0110] Furthermore, in this embodiment, even if the build plate is bent, the first and second portions can be raised and lowered by the lifting mechanism, so high levelness can be easily achieved. Furthermore, when such a build plate is incorporated into a three-dimensional molding device, fully automatic level calibration is possible. Conventionally, when manufacturing a three-dimensional molding device, skilled engineers were required to ensure that the build plate was perfectly level. Furthermore, care had to be taken to ensure that the levelness of the build plate was perfectly maintained during transportation, installation, use, and the like of the three-dimensional molding device. In contrast, with the build plate of the present invention, the levelness of the build plate can be calibrated by automatic operation of the lifting mechanism. Therefore, it is only necessary to calibrate the levelness before each use, which is extremely advantageous in the manufacture, transportation, installation, and the like of three-dimensional molding devices.

[0111] The three-dimensional molding device incorporating the build plate of the present invention is less susceptible to the effects of thermal expansion and can easily achieve high levelness, so it was found to be able to produce very precise and beautiful objects when compared to conventional three-dimensional molding devices at the same molding speed. Although it was expected that thermal expansion and / or levelness would affect the molded object, the precision of the molded object was different to a level that was easily distinguishable by appearance, which was beyond expectations.

[0112] As a second embodiment of the third aspect of the present invention, the build plate can be raised and lowered by at least three lifting mechanisms.

[0113] In this embodiment, the build plate can be raised and lowered by a total of three lifting mechanisms, thereby achieving high levelness in the X-Y plane. That is, in this embodiment, the build plate, which is located in the X-Y plane, is raised and lowered in the Z direction by one lifting mechanism, while the two lifting mechanisms can adjust the levelness in the X-Y plane in both the X-Z and Y-Z directions. Adjusting the levelness of the build plate using a total of two lifting mechanisms requires a configuration that prevents displacement in either the X-Z or Y-Z directions, which requires the use of expensive components such as linear guides. Therefore, the second embodiment, which allows fine adjustment of displacement in both directions using three lifting mechanisms, is particularly advantageous.

[0114] As a third embodiment of the third aspect of the present invention, the first portion of the lower plate can be raised and lowered by at least two lifting mechanisms, and the second portion of the lower plate can be raised and lowered by at least one lifting mechanism.

[0115] In such an embodiment, the first portion of the lower plate can extend in either the X direction or the Y direction and be liftable at both ends by the lifting mechanism, while the second portion of the lower plate can be positioned in a direction in which the first portion is not present. For example, the first portion of the lower plate can extend in the X direction and be connectable to the lifting mechanism at both ends, while the second portion of the lower plate can extend to the end in the Y direction in which the first portion is not present and be connectable to the lifting mechanism at the end in the Y direction. Such an embodiment is advantageous because it allows the build plate of the present invention to be configured very simply.

[0116] As a fourth embodiment of the third aspect of the present invention, the build plate further includes a heater for heating the upper plate.

[0117] In such an embodiment, the top plate would be particularly susceptible to thermal expansion, which would be less susceptible with the build plate configuration of the present invention, making the build plate configuration of the present invention particularly advantageous.

[0118] In a fifth embodiment of the third aspect of the present invention, the upper plate of the build plate is in contact with the lower plate via a spherical member. Note that the spherical member does not need to be a perfect sphere, and may have a curved cross section within a range that achieves the desired effect.

[0119] In such an embodiment, the upper plate and the spherical member are in point contact, and the spherical member and the lower plate are also in point contact. This allows the upper plate to slide easily from the lower plate, and heat transfer from the upper plate to the lower plate can be minimized. Furthermore, even if an external force is applied to the upper plate, the upper plate can tilt slightly on the spherical member. This is preferable because it makes the upper plate less susceptible to damage, etc. Even if the upper plate tilts, this build plate can be fully automatically calibrated to be horizontal when incorporated into a three-dimensional molding device, and three-dimensional molding can be performed without any problems by performing this calibration.

[0120] A sixth embodiment of the third invention relates to a three-dimensional molding device comprising a build plate as described above, a tool head that is horizontally movable above the build plate, at least two lifting mechanisms for raising and lowering the build plate, a molding material supply mechanism that supplies molding material to the tool head, a levelness measurement mechanism that measures the levelness of the build plate, and a control device that controls the operation of these mechanisms.

[0121] The three-dimensional molding apparatus of the present invention uses a levelness measurement mechanism to measure the level of the build plate, and the lifting mechanism can adjust the levelness based on this information. As described above, the three-dimensional molding apparatus of the present invention is highly advantageous in that it can automatically calibrate the levelness either before each use or during use. Furthermore, as described above, the three-dimensional molding apparatus of the present invention is highly advantageous in that it can produce unexpectedly precise and beautifully molded objects.

[0122] A seventh embodiment of the third invention relates to a three-dimensional molding method using the three-dimensional molding device described above, including a step of measuring the level of the build plate using the level measurement mechanism, a step of the control device adjusting the level of the build plate using the lifting mechanism based on the level information, and a step of providing the modeling material to the tool head using the modeling material providing mechanism, and the tool head forming a model.

[0123] According to the method of this embodiment, the build plate can be automatically leveled at the start of each molding operation, eliminating the need for time-consuming manual adjustments and eliminating the need to pay special attention to the levelness of the build plate of the three-dimensional molding device from the time of manufacture to daily use. Furthermore, since the build plate can always be kept level when molding a model, it is possible to manufacture a model with precision and beauty, which is extremely advantageous.

[0124] DESCRIPTION OF SYMBOLS 1...Three-dimensional molding device 100...Housing 10...Upper surface 20...Lower surface 21...Second opening 30...Front surface 31...Handle 40...Rear surface 41, 42...Third opening 50...Right side surface 51...First opening 52...First fan 60...Left side surface 200...Tool head 300...XY mechanism 301, 302...Belt 310...X bar 321, 322...Y bar 321a...Rail 321b...Block 331, 332, 331a, 331b...Pulley 341, 342...Belt tensioner 351, 352...Motor 400...XY plate 500...Build plate 501...Fixed portion 502...Spherical member 503...Bolt 504...Washer 505...Elastic member 506...Nut 507...Spacer 508...Fixing spring 510...Upper plate 510x...Mounting bolt 520...Lower plate 520a...First part of lower plate 520b...Second part of lower plate 520x...Mounting hole 530...Lifting mechanism 531...Slide screw 532...Linear bushing 533...Motor 600...Chamber blower 610...Air intake 620...Fan 630...Duct 640...Air outlet 700...Power supply 710...Power supply fan (second fan) 800...Control device 810...Control device fan (second fan) A...Chamber B...Electrical equipment space C...Upper space

Claims

1. A three-dimensional shaping apparatus comprising: a tool head for melting a filament; a tool head moving mechanism for moving the tool head; a build plate on which a shaped object discharged from the tool head and formed is placed; a chamber for storing at least the tool head and the build plate; a chamber blower for stirring air in the chamber and cooling the shaped object; and a power source and a control device for operating these components, wherein the chamber blower has an air intake for taking in air in the chamber, a fan for sucking air from the air intake, a duct which is a flow path of the air sucked from the fan, and an air outlet for sending air from the duct to the shaped object, and the fan and the duct are located outside the chamber.

2. The three-dimensional shaping apparatus according to claim 1, wherein the fan and the duct of the chamber blower are located in an electrical equipment space where the power source and / or the control device is present.

3. The three-dimensional shaping apparatus according to claim 2, further comprising a fan for introducing outside air to cool the power source and / or the control device, wherein the power source, the control device, and the motor of the tool head moving mechanism are located in the electrical equipment space.

4. The three-dimensional shaping apparatus according to claim 1, wherein the tool head moving mechanism is an XY mechanism for horizontally moving the tool head, and further comprises a lifting mechanism for raising and lowering the build plate.

5. The three-dimensional shaping apparatus according to claim 4, further comprising an XY plate for arranging the XY mechanism, wherein the XY plate is located outside the upper part of the chamber, and the upper part of the chamber is substantially open.

6. The three-dimensional shaping apparatus according to claim 1, wherein a heater is attached to the build plate, and the build plate has an upper plate and a lower plate, the upper plate is fixed in a slidable state with respect to the lower plate, and the lower plate is at least divided into a first part and a second part, and each of them can be raised and lowered by a lifting mechanism.

7. The three-dimensional shaping apparatus according to claim 1, further comprising a VOC filter for removing VOC in the chamber.

8. The three-dimensional molding apparatus according to claim 1, further comprising a housing having a first opening through which outside air can be inhaled and a second opening through which internal air can be discharged, and a first fan for introducing the outside air inhaled through the first opening into the chamber.

9. The three-dimensional molding apparatus according to claim 1, having a second fan for introducing outside air into the electrical equipment space to cool the power supply and / or the control device, wherein the power supply, the control device, the motor of the tool head moving mechanism, and the fan and duct of the chamber blower are located in the electrical equipment space outside the chamber.

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