JP2001334582A - Three-dimensional molding apparatus and three- dimensional molding process - Google Patents

Abstract

PROBLEM TO BE SOLVED: To perform appropriate molding by detecting abnormality of a nozzle in three-dimensional molding for forming a three-dimensional molded article by providing a binder to a powder from a nozzle. SOLUTION: In a three-dimensional molding apparatus by which on every formation of a powder layer 80, by extruding a binder from a nozzle assembly 220, powder-bound bodies 81 are successively formed to form a three-dimensional molded article, the binder is extruded from a plurality of the nozzles 221 toward a specified region 83 for inspection on the powder layer and an image of the region 83 for inspection is obtained by using a scanner 25. Then, by analyzing the image, an abnormal nozzle in which clogging of the nozzle is generated is specified. When the abnormal nozzle exists, a cleaning liquid is fed to the nozzle 221 from a tank 212 for the cleaning liquid to perform cleaning. It is possible thereby to prevent an inappropriate three-dimensional molded article caused by existence of the abnormal nozzle from being formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a three-dimensional printing technique, and more particularly to a three-dimensional printing technique for producing a three-dimensional printing object by applying a bonding material and binding powder. is there.

[0002]

2. Description of the Related Art Heretofore, a three-dimensional model of a modeling object has been obtained by sequentially bonding thin layers of powder corresponding to respective cross sections obtained by cutting a three-dimensional modeling object by a plurality of parallel surfaces using a bonding material. 2. Description of the Related Art A technique for generating a shaped object is known.

[0003] Such a technique can be used for component prototyping called rapid prototyping, such as that disclosed in Japanese Patent No. 2729110. The specific procedure of this three-dimensional modeling will be described below.

First, a thin layer of powder is spread evenly on a flat surface by a blade mechanism. Next, a binder (bonding material) is discharged by scanning the nozzle head to a predetermined region in the thin layer of the powder. The powder material in the region from which the binder has been discharged is brought into a bonding state and is also bonded to the already formed lower layer. Then, the steps of sequentially depositing the powder layer on the upper portion and discharging the binder are repeated until the entire model is completed. Eventually, the areas where the binder was not applied are in a state where the powders are individually independent, that is,
Since the objects are not connected to each other, the objects are dropped and dropped to be separated from the apparatus. As described above, a desired three-dimensional structure can be obtained.

[0005]

However, when modeling is performed using a nozzle, there is a problem that the binder solidifies and clogs the nozzle. When nozzle clogging occurs, a region where the binder is not applied to the powder layer is generated, and the strength of the three-dimensional structure is reduced and the three-dimensional structure is easily broken.

Accordingly, the present invention has been made in view of the above problems, and has as its object to prevent generation of an inappropriate three-dimensional structure.

[0007]

According to the first aspect of the present invention, there is provided a three-dimensional printing apparatus for generating a three-dimensional printing object corresponding to a printing target object by applying a bonding material to a powder material and bonding the powder material to each other. A layer forming means for sequentially laminating layers of the powder material, and applying a bonding material to the layer each time the layer forming means forms a layer of the powder material, so that the object to be modeled is formed in parallel. The apparatus includes an applying unit that sequentially forms a combined body of the powder materials corresponding to the cut surfaces cut by the plurality of surfaces, and a detecting unit that detects an abnormality in applying the bonding material by the applying unit.

According to a second aspect of the present invention, there is provided the three-dimensional printing apparatus according to the first aspect, wherein the detecting means obtains an observation result by observing the bonding material applied to a predetermined area by the applying means. Means for determining a state of the providing means based on the observation result.

According to a third aspect of the present invention, there is provided the three-dimensional printing apparatus according to the second aspect, wherein the applying means has a plurality of nozzles for discharging a bonding material, and the judging means has the observation result. Then, an abnormal nozzle included in the plurality of nozzles is specified.

According to a fourth aspect of the present invention, in the three-dimensional modeling apparatus according to the third aspect, the specified abnormal nozzle discharges the bonding material from another normal nozzle to a position where the bonding material is to be discharged. The apparatus further includes a discharge control unit.

According to a fifth aspect of the present invention, there is provided the three-dimensional modeling apparatus according to the first or second aspect, further comprising a recovery unit that recovers the applying unit when the abnormality is detected by the detection unit. Prepare.

The invention according to claim 6 is the three-dimensional printing apparatus according to claim 5, wherein the restoring means cleans the applying means using a cleaning liquid.

According to a seventh aspect of the present invention, in the three-dimensional modeling apparatus according to the sixth aspect, the applying means has a nozzle for discharging a bonding material, and the restoring means supplies a cleaning liquid to the nozzle. Supply and discharge.

According to an eighth aspect of the present invention, there is provided the three-dimensional modeling apparatus according to the sixth or seventh aspect, wherein the restoring means periodically cleans the applying means.

According to a ninth aspect of the present invention, there is provided a three-dimensional modeling method for generating a three-dimensional modeled object corresponding to a modeling object by applying a binding material to a powdery material and bonding the powdered material, wherein (a) A step of forming a layer, and (b) applying a bonding material to the layer using an application unit, thereby forming a bonded body of the powder material corresponding to a cut surface obtained by cutting the modeling object on one surface. By repeating the steps (a) and (b), (c) the steps (a) and (b) are sequentially performed to form a combined body of the powder material corresponding to a cut surface obtained by cutting the modeling object by a plurality of parallel surfaces, and The method includes a step of generating a three-dimensional structure and a step of (d) detecting an abnormality with respect to the application of the bonding material by the application unit by the detection unit.

According to a tenth aspect of the present invention, in the three-dimensional modeling method according to the ninth aspect, the applying means has a plurality of nozzles for discharging a bonding material, and the step (d) comprises the step of (d) -1) discharging the bonding material from the plurality of nozzles toward a predetermined area, and (d-2) observing the bonding material discharged to the predetermined area, the bonding material is included in the plurality of nozzles. Identifying the abnormal nozzle.

According to an eleventh aspect of the present invention, in the three-dimensional molding method according to the tenth aspect, when the abnormal nozzle is specified in the step (d-2), the abnormal nozzle is determined in the step (a). Discharges the bonding material from another normal nozzle to the position where the bonding material is to be discharged.

[0018]

DESCRIPTION OF THE PREFERRED EMBODIMENTS <1. Main Configuration of Three-Dimensional Modeling Apparatus> FIG. 1 is a schematic diagram showing a three-dimensional modeling apparatus 100 according to one embodiment of the present invention. In FIG. 1, XYZ directions defined for the sake of explanation are also indicated by arrows. Also,
Figure 3 shows a cross section of a detail without parallel diagonal lines.

The three-dimensional modeling apparatus 100 includes a control unit 10 and a binder providing unit 20, a modeling unit 30, a powder supply unit 40, a powder diffusion unit 50, and an infrared lamp 60, which are electrically connected to the control unit 10, respectively. Prepare.

The control unit 10 includes a computer 11 and a drive control unit 12 electrically connected to the computer 11.

The computer 11 is a general desk-top type computer or the like which is internally provided with a CPU, a memory and the like. The computer 11 converts the shape of the three-dimensional object into model data as model data, and outputs to the drive control unit 12 cross-sectional data obtained by slicing the data into thin parallel cross-sections.

The drive control unit 12 includes a binder applying unit 20,
Control means for driving each of the modeling unit 30, the powder supply unit 40, the powder diffusion unit 50, and the lamp 60. When the drive controller 12 obtains the cross-sectional data from the computer 11, the drive controller 12 gives a drive command to each of the above-described units based on the cross-sectional data, thereby sequentially forming a powdered composite of each powder material in the modeling unit 30. Overall control of operation.

The binder applying section 20 discharges the tank section 21 containing a liquid binder (which is a binding material and may be an ordinary adhesive), discharges the binder in the tank section 21 or discharges the binder. Head 22 that reads the image with a scanner, and the nozzle head 22 is horizontally XY
An XY direction moving unit 23 that moves on a plane is provided.

The XY direction moving section 23 includes a guide rail 231 extending in the X direction and a guide rail 2 extending in the Y direction.
32, and the guide rail 232 is a guide rail 231.
Makes it possible to move in the X direction. The nozzle head 22 is attached to the guide rail 232 and is movable in the Y direction. A motor is attached to each of the guide rails 231 and 232, and moves the nozzle head 22 in a plane defined by the X axis and the Y axis via a timing belt or a ball screw. That is, the nozzle head 22 can be moved to any position on the XY plane on the modeling unit 30 under the control of the drive control unit 12.

The shaping section 30 includes a shaping section main body 31 having a concave portion at the center, a shaping stage 32 provided inside the concave portion of the shaping section main body 31, and a shaping stage 32 via a support rod 33. And a driving unit 34 for moving in the direction.

The modeling unit main body 31 serves to provide a work area for generating the three-dimensional modeled object 91. Also,
The modeling unit main body 31 has a powder temporary placement unit 31b that temporarily holds the powder supplied from the powder supply unit 40 at the upper part.

The modeling stage 32 has a rectangular shape in the XY section, and its side surface is in contact with the vertical inner wall 31 a of the concave portion in the modeling portion main body 31. Then, the rectangular parallelepiped three-dimensional space formed by the modeling stage 32 and the vertical inner wall 31a of the modeling unit main body 31 becomes the modeling space 300 in which the three-dimensional modeled object 91 is generated. That is, the binder is discharged from the nozzle head 22 to join the powder on the modeling stage 32 to form a modeled object.

The powder supply section 40 includes a tank section 41, a cutoff plate 42 provided at an outlet of the tank section 41, and a drive section 43 for sliding the cutoff plate 42 according to a command from the drive control section 12.

The tank 41 contains white powder. This powder is a material for forming a three-dimensional structure, and for example, (cellulose-) starch powder, gypsum powder, resin powder and the like are used.

The shut-off plate 42 is slidable in the horizontal direction (X direction), and supplies and stops the powder stored in the tank 41 to the powder temporary placing part 31b of the modeling part 30. .

The powder diffusion unit 50 includes a blade 51, a guide rail 52 for regulating the operation of the blade 51, and a driving unit 53 for moving the blade 51.

The blade 51 has a blade-like shape that is long in the Y direction and has a sharp lower end. The length of the blade 51 in the Y direction is a length that can cover the width of the molding space 300 in the Y direction. I have. In addition, a vibration mechanism for giving a minute vibration to the blade may be added so that the powder can be smoothly diffused by the blade 51.

The driving section 53 has a vertical driving section 53a for vertically moving the blade 51 in the vertical direction (Z direction) and a horizontal driving section 53b for reciprocating the blade 51 in the horizontal direction (X direction). Then, the drive control unit 12
The vertical drive unit 53a and the horizontal drive unit 53b are driven based on the command from the controller 51, and the blade 51 moves in the X and Z directions.

The infrared lamp 60 is for evaporating water or a solvent contained in the binder to promote the binding of the powder to which the binder has been applied. Drive control unit 12
, The infrared lamp 60 is turned on and off. When a thermosetting binder is used, the infrared lamp 60 functions as a means for curing the binder. A microwave generator may be provided instead of the lamp 60.

A discharge container 70 is arranged on the side of the shaping section 30, and receives a cleaning liquid discharged when cleaning the nozzles of the nozzle head 22 as described later. The discharge container 70 is connected to a drain for discharging the used cleaning liquid out of the apparatus.

FIG. 2 shows the tank 21 and the nozzle head 2.
FIG. 2 is a diagram showing an internal configuration of the second embodiment and a functional configuration of a drive control unit 12 related to these configurations.

The tank section 21 includes a plurality of tanks (four tanks in this example) 211 for storing binders of different colors, and a tank 212 for storing a cleaning liquid for cleaning the nozzles. Tank 21 for binder
Each of the color filters 1 contains a binder colored in three primary colors of Y (yellow), M (magenta), and C (cyan) and W (white) (hereinafter, referred to as a “colored binder”). You. Here, the colored binder is
It is desirable to use one that does not discolor even when combined with the powder and does not discolor or fade even after a long time.

The nozzle head 22 movable in the X and Y directions by the XY direction moving section 23 includes a nozzle assembly 220 having a plurality of nozzles 221 for discharging a binder, and a binder (landing dot) discharged from the nozzle 221. ) Is provided as a scanner.

The nozzle assembly 220 has four tubes 24
1 is connected to the tank 211 for the binder,
A binder is supplied to each nozzle 221 from one of the tanks 211. The nozzle 221 discharges (spouts) each binder as minute droplets by, for example, an inkjet method.
The ejection of the binder is individually controlled by the drive control unit 12. The binder discharged from each nozzle 221 adheres to the powder layer 80 in the modeling unit main body 31 provided at a position facing the nozzle head 22.
As a result, a part of the powder layer 80 becomes the combined body 81 of the powder.

In the middle of the tube 241 is provided a flow switching unit 242 having a plurality of valves. The cleaning liquid tank 212 is connected to the flow switching unit 242 via a tube 243, and the cleaning liquid from the tank 212 can be supplied to the nozzle assembly 220 by the flow switching unit 242.

The drive control unit 12 has a movement control circuit 121 as an interface with the nozzle head 22,
A discharge control circuit 122, a valve control circuit 123, and a receiving circuit 124 are provided.

The movement control circuit 121 includes an XY direction movement unit 23
Is controlled by controlling the position of the nozzle head 22, and the discharge control circuit 122 controls the discharge of the binder of each color from the nozzle head 22 (nozzle assembly 220).
The valve control circuit 123 controls the operation of the valve of the flow path switching unit 242, and the receiving circuit 124 receives an image signal from the scanner 25.

The drive control unit 12 supplies signals to each control circuit to cause the nozzle head 22 to perform a series of operations.
And a cleaning control unit 127. These control units are functions realized by the CPU in the drive control unit 12 executing arithmetic processing according to a program in the ROM. Note that these functional configurations may be realized by the computer 11, and all or a part of the functions may be implemented by the drive control unit 1.
2 may be realized by a dedicated electric circuit.

The binder discharge control section 125 supplies a signal to the movement control circuit 121 and the discharge control circuit 122 to cause the nozzle head 22 to execute a series of operations for generating the three-dimensional structure 91. The inspection control unit 126 gives a signal to the movement control circuit 121 and the ejection control circuit 122 to form a binder pattern in a predetermined inspection area 83,
By causing the scanner 25 to scan the inspection area 83, a signal indicating an image of the inspection area 83 is received by the receiving circuit 1.
Acquisition via 24. The cleaning control unit 127 includes a movement control circuit 121, a discharge control circuit 122, and a valve control circuit 12.
3 to the nozzle head 22 as shown in FIG.
The nozzle 2 is moved above the discharge container 70 shown in FIG.
The cleaning liquid is supplied to 21.

FIG. 3 is a diagram showing the internal configuration of the scanner 25. The first lens 251 and the first lens 251 on which light from the inspection area 83 enters the scanner 25 in order along the optical axis 25J.
A mirror 252 that reflects light from the lens 251, a second lens 253 that collects light from the mirror 252, and
It has a light receiving unit 254 that receives light from the second lens 253. The light receiving section 254 has a one-dimensional light receiving element array (long in a direction perpendicular to the paper surface), and the scanner 25 moves on the inspection area 83 together with the nozzle head 22 to acquire an image of the inspection area 83. Done.

FIG. 4 is a block diagram showing the configuration of the computer 11 of the control unit 10 together with peripheral devices. The computer 11 has a configuration similar to that of a general-purpose computer, and is connected to a display 111 for displaying various information as a peripheral device, and an input unit 112 such as a keyboard and a mouse for receiving a user's operation.

The computer 11 is pre-installed with a program for causing the computer 11 to execute various operations related to three-dimensional printing via the recording medium 8 such as an optical disk, a magnetic disk, a magneto-optical disk, and a memory card.

As shown in FIG. 4, the computer 11 includes a CPU 101 for performing various arithmetic processing, a ROM 102 for storing a basic program, an operation program 141, section data 131 to be described later, and image data 13 from the scanner 25.
2. The configuration is such that the inspection data 133 and the like, which are the inspection results of the nozzles, are stored, and the RAM 103 and the like, which are working areas for arithmetic processing, are connected to the bus lines. The bus line also includes a fixed disk 10 for storing a display 111, an input unit 112, various programs including a program 141, model data 142 indicating the shape of a modeling object, and the like.
4. a reading unit 10 for reading a program or the like from the recording medium 8
5, and a communication unit 106 that exchanges information with the drive control unit 12 is connected via an interface (I / F) as appropriate.

The program 141 is fetched from the reading unit 105 to the fixed disk 104, and the program 141
Is copied to the RAM 103. And the CPU 101
Performs arithmetic processing in accordance with the program 141, so that the configuration centered on the computer 11 functions as a part of the control unit 10.

FIG. 5 is a block diagram showing a main functional configuration of the computer 11. In FIG. 5, the functions of the cross-section data generation unit 181, the control signal generation unit 182, and the inspection unit 183 realized by the CPU 101 in FIG. Some or all of these functional components may be configured as a dedicated electric circuit, and the computer 11 may be a dedicated computer for three-dimensional printing. The details of each functional configuration will be described later together with the description of the operation of the three-dimensional printing apparatus 100.

<2. Operation of Three-Dimensional Modeling Apparatus> FIGS. 6 and 7 are flowcharts for explaining the outline of the operation of the three-dimensional modeling apparatus 100. Hereinafter, the operation of the three-dimensional printing apparatus 100 will be described with reference to FIGS. 1 and 2 and FIGS. 5 to 7.

In step S11, the computer 11
Creates model data 142 representing a three-dimensional object having a color pattern or the like on its surface. The model data 142 that is the basis for modeling includes a general three-dimensional C
Color three-dimensional model data created by AD modeling software can be used. It is also possible to use data and texture of a three-dimensional shape measured by the three-dimensional shape input device. The generated model data 142 is stored on the fixed disk 104 as appropriate.

In the model data 142, there are data in which color information is provided only on the surface of the three-dimensional model or data in which color information is provided up to the inside of the model. In the latter case, it is possible to use only the color information of the model surface at the time of modeling, and it is also possible to use the color information inside the model. For example, when generating a three-dimensional structure such as a human body model, there is a case where it is desired to apply a different color to each internal organ, and in that case, color information inside the model is used.

When the model data 142 is prepared, information relating to the layer thickness of the powder (slice pitch at the time of creating the cross-sectional data) and the number of layers (the number of the cross-sectional data sets) at the time of forming the modeling object are set data. As the input unit 112
And stored in the RAM 103 (step S12). Note that the pitch for slicing can be changed within a predetermined range (a range of a thickness capable of binding the powder).

Next, as shown in FIG. 5, the section data generator 181 generates section data 131 for each section obtained by horizontally slicing the object to be formed from the model data 142 based on the setting data and the model data 142. Then R
It is stored in the AM 103 (step S13). The cross-section data 131 is generated from the model data by cutting out a cross-section body sliced at a pitch corresponding to the thickness of one layer of the powder to be laminated, and as shape data and coloring data indicating a region where the cross-section exists.

FIG. 8 is a diagram showing an example of the state of the generation of the section data in step S13. First, FIG.
FIG. 8 includes color information from the model data shown in FIG.
The cross section shown in (b) is cut out and subdivided into a grid.
It is treated in the same way as a two-dimensional image bitmap.
As shown in (c), it is converted into bitmap information for each color. This bitmap information is information taking into account the gradation and the like. In FIG. 8C, shape data is data indicating an area where a cross section exists, and Y data, C data,
M data and W data correspond to coloring data.

In this embodiment, since the color of the powder is white, no coloring is required for the white portion. However, a binder was required for modeling, and a white binder was applied to this portion, and W data was given. When there is no color information inside the three-dimensional model, W data is also added to a portion corresponding to the inside. Therefore, when the OR of the YCMW data is ORed, the entire cross-sectional shape is filled. Further, in order to clearly produce black color, a black binder may be prepared, and coloring data corresponding to black may be used.

FIGS. 9A to 9C are views showing an example of the state of the generation of the section data in step S13, as in FIG. Note that, in FIG. 9C, the illustration of the coloring data is omitted, and the shape data shows only the region where the cross section exists. In FIG. 9C, in the model data, a portion that does not contribute to three-dimensional modeling, that is, a portion corresponding to an internal region that does not appear in the outer shape is deleted from the shape data as a modeling unnecessary portion. As a result, the operation of combining the powder with the binder is not performed in the unnecessary part of the molding,
Binder can be saved.

When the preparation of the section data 131 is completed, the setting data is transferred from the communication section 106 of the computer 11 to the drive control section 12 (step S14). Thus, the amount of powder supplied from the powder supply unit 40 per one time, the amount of movement of the modeling stage 32 per one time, and the like are set.

[0060] The drive control unit 1 is executed after the next step S21.
Reference numeral 2 denotes a modeling operation performed by controlling each unit. FIG. 10 is a conceptual diagram illustrating these operations.

In step S 21, the molding stage 32 is supported by the support rod 33 to form a combined body of the Nth layer (N = 1, 2,...) Of the powder in the molding stage 32.
It is lowered and held by a predetermined distance in the direction of arrow DN shown in FIG. The descending distance is a distance corresponding to the lamination thickness input from the computer 11. As a result, a space SP for forming one new powder layer is formed above the powder layer that has been deposited on the modeling stage 32 and has completed the necessary bonding. Where N = 1
In this case, the space SP is formed on the upper surface of the modeling stage 32 because it corresponds to the formation of the first layer.

In step S22, a powder as a material in forming a three-dimensional structure is supplied. Here, FIG.
0 (a), the shutoff plate 42 of the powder supply unit 40 slides from the closed position to drop a predetermined amount of the powder in the tank unit 41 to the powder temporary storage unit 31b of the modeling unit main body 31. As the predetermined amount, an amount slightly larger than the volume of the space SP (the required amount of powder in molding) is set.
After the supply of the predetermined amount of powder is completed, the shut-off plate 42 returns to the closed position and stops supplying the powder.

In step S23, a thin layer is formed using the powder supplied in step S22. Here, as shown in FIG. 10A and FIG.
By moving the powder deposited on b in the X direction by the blade 51, the powder enters the space SP on the modeling stage 32, and a thin uniform powder layer is formed. At this time, the lower end of the blade 51 is connected to the uppermost surface 31 c of the modeling unit main body 31.
Move along. As a result, a thin layer of powder having a predetermined thickness is accurately formed. Then, after the powder layer is formed, the blade 51 is separated from the uppermost surface 31c by the vertical driving unit 53a (see FIG. 1), passes over the powder layer by the horizontal driving unit 53b, and returns to the initial position.

In step S24, the binder discharge control unit 125 (see FIG. 2) drives the XY-direction moving unit 23 via the movement control circuit 121 in accordance with the shape data and the coloring data created in step S13, whereby
As shown in FIG. 0 (c), the nozzle head 22 (the nozzle assembly 220) is moved in the XY plane. Then, during the movement, the binder discharge control unit 125 sends a signal to the discharge control circuit 122 based on the chromatic data to cause the nozzles 221 to discharge the colored binder appropriately. As a result, a powder combined body 81 is generated. Note that the powder 82 to which the binder is not applied is kept in an independent state.

In step S24, when discharging the binder for the portion corresponding to the surface portion of the three-dimensional modeled object, Y and Y are determined based on coloring data derived from the modeled object.
Control is performed so as to selectively discharge the M, C, and W colored binders. Thereby, color modeling of a three-dimensional model can be performed. On the other hand, in a portion of the three-dimensional structure that does not need to be colored (coloring unnecessary region), the molding is performed by discharging a W colored binder that does not hinder the coloring state of the colored portion.

FIG. 11 is a diagram showing the state of movement of the nozzle assembly 220. In FIG. 11, reference numeral 2211 denotes each nozzle 2
21 shows the position of the discharge port 21. Nozzle assembly 220 is YM
The CW has a row of nozzles 221 for each color, and each row has six nozzles 221 arranged therein, which is an aggregate of a total of 24 nozzles 221. The combination of the nozzles 221 of each color of YMCW forms six rows as indicated by reference numerals L1 to L6.

The Y direction shown in FIG.
, And the X direction is the sub-scanning direction. These directions correspond to the X and Y directions shown in FIG. While moving the nozzle assembly 220 in the main scanning direction,
Each time the nozzle 221 moves by the nozzle pitch P1,
And discharges the binder selectively and intermittently. As a result, a binder of each color of YMCW is sequentially applied to each region of the powder layer, and coloring and bonding of the powder are performed.

When one movement in the main scanning direction is completed, the nozzle assembly 220 moves P2 (row L1 to row L
6 and the distance between adjacent nozzles in the row direction) and return to the main scanning start position in the Y direction, and the movement in the main scanning direction is started again. By repeating such an operation, the main scanning and the sub-scanning of the nozzle head 22 are performed, and the binder of each color is sequentially applied to each region of the powder layer.

By scanning only the area where the shape data exists, the time required for applying the binder can be reduced.

Further, in order to make the spread of the binder attached to the powder layer uniform and to secure the strength of the formed object, it is preferable to uniformly apply the same amount of binder per unit area to the formed portion. For example, if the moving speed of each nozzle 221 by the XY-direction moving unit 23 multiplied by the amount of binder discharged from each nozzle 221 per unit time (for example, the number of binder droplets) is fixed, the unit is The same amount of binder per area can be applied uniformly.

Here, whether or not an abnormal nozzle exists is confirmed by referring to the inspection data 133 generated in advance (step S25).
And the operation when an abnormal nozzle exists (step S
28) will be described later.

After the discharge of the binder is completed, the discharge operation of the binder is stopped, and the XY-direction moving unit 23 is driven.
The nozzle head 22 returns to the initial position.

In step S26, the powder to which the binder is attached is dried and joined. Drying is performed by irradiating the infrared lamp 60 from above the thinly stretched powder layer. Thereby, the binder adhering to the powder dries quickly. In the case of a binder that is quickly cured by natural drying, irradiation with an infrared lamp or the like is unnecessary. By step S26, the formation of the cross section of one layer of the three-dimensional structure is completed.

When the formation of one layer is completed, step S27
Then, the drive control unit 12 determines whether or not the processing for the number of laminations is completed based on the number of laminations indicated by the setting data (that is, determines whether the modeling of the three-dimensional structure is completed). ), If "NO" is determined, step S2 is performed.
The processing from step 1 is repeated, and if it is determined to be “YES”, the modeling operation ends. When the shaping of the three-dimensional structure is completed, the powder to which the binder is not provided is separated, and a combined body (three-dimensional structure) of the powder bound by the binder is taken out. The unbound powder may be collected and reused as a material.

When the process returns to step S21, an operation of forming a new powder composite of the (N + 1) th layer on the upper side of the (N) th layer is performed. By repeating such an operation by the number of layers, the colorized combined body for each layer is sequentially stacked on the stage 32, and finally, a three-dimensional structure of the object to be formed is formed on the formation stage 32. You.

<3. Nozzle inspection and operation after inspection>
FIG. 12 is a flowchart showing a flow of the operation of the three-dimensional printing apparatus 100 when the three-dimensional printing apparatus 100 inspects the presence or absence of nozzle clogging. The operation illustrated in FIG. 12 may be performed before or after the modeling operation illustrated in FIGS. 6 and 7. Further, it may be performed during the molding operation. That is, the operation related to the nozzle inspection is an operation independent of the molding operation. The timing at which the nozzle inspection is performed is input to the computer 11 in advance by the operator.

In the inspection of the nozzle 221, first, the inspection control unit 126 (see FIG. 2) sends a signal to the movement control circuit 121 to move the nozzle head 22 to the predetermined inspection area 83.
It moves to the inspection position above (see FIG. 2) (step S31). As the inspection area 83, an area on the powder layer that is not a modeling object is appropriately set. Thereafter, each nozzle 2 of the nozzle assembly 220 is moved toward the inspection area 83.
The binder is discharged from 21 (step S32).

FIG. 13 is a diagram showing a state of the binder applied to the inspection area 83 when all the nozzles 221 are normal. Note that, in FIG. 13, as in FIG.
L6 and the letters Y, M, C, and W indicate the discharge positions of the binders of the respective colors. Further, when the modeling is actually performed, no gap is formed between the binders discharged from the plurality of nozzles 221, but the state of each discharged binder is shown by a circle in FIG. 13.

As shown in FIG. 13, all the nozzles 221
Is normal, each binder is applied neatly in 6 rows and 4 columns. On the other hand, in FIG. 14, an abnormality (nozzle clogging) occurs in the nozzle 221 corresponding to the row L3 of the column Y, the row L5 of the column M, the row L6 of the column C, and the row L2 of the column W, and ejection is performed. The state of the inspection area 83 when there is no such area is shown.

When the binder is discharged from each nozzle 221, the state of the inspection area 83 illustrated in FIGS. 13 and 14 is read while the scanner 25 scans (step S33). The read image of the inspection area 83 is transferred from the receiving circuit 124 shown in FIG. 2 to the computer 11 via the inspection control unit 126. That is, the binder discharged to the inspection area 83 is observed using the scanner 25, and the observation result is obtained as image data.

The image data 132 transferred to the computer 11 is transmitted to the RA via the communication unit 106 as shown in FIG.
It is recorded in M103 and analyzed by the inspection unit 183 (step S34). Specifically, regions corresponding to the respective ejection positions of the image of the inspection region 83 are extracted, and it is confirmed whether the color of the extracted region is the color of the binder. Then, it is determined whether or not each nozzle 221 is functioning normally, and an abnormal nozzle is specified. Accordingly, the state of the nozzle assembly 220, which is a mechanism for applying a binder, is determined, and abnormality detection of the nozzle assembly 220 is realized.

Although it has been described that a white powder is used as the powder, the white binder has a vivid white color. Therefore, the powder having the white binder and the powder not having the binder have different colors in the image. Colors are slightly different. Inspection of a white binder is performed based on this subtle color difference. Of course, a powder having a color different from the color of each binder may be used as the powder.

As a result of the inspection, when it is confirmed that all the nozzles 221 are normal, the inspection result is stored in the RAM 103 as the inspection data 133, and the inspection operation is completed (steps S35 and S36).

If the result of the test that any one of the nozzles 221 is clogged with the binder and an abnormal nozzle exists is obtained, the nozzle 221 is cleaned in principle (step S38).

In the cleaning operation, first, the cleaning control unit 127 shown in FIG. 2 sends a signal to the movement control circuit 121 to move the nozzle head 22 above the discharge container 70 (see FIG. 1). Then, the flow path switching unit 24 is controlled by the valve control circuit 123.
By operating the second valve, each nozzle 221 is connected to the tank 222 for the cleaning liquid by the tube 243. Tank 21
2 has a function of forcibly sending out the cleaning liquid, whereby the cleaning liquid is forcibly supplied to the nozzle 221,
Nozzle clogging is eliminated. The cleaning liquid discharged from the nozzle 221 is received by the discharge container 70 and discharged to the outside of the apparatus via the drain.

As described above, in the three-dimensional printing apparatus 100, cleaning is realized by a simple operation of discharging the cleaning liquid from the nozzle 221.

After the cleaning, the nozzle 221 is inspected again (steps S31 to S34). As a result of the inspection, if the result that all the nozzles 221 are normal is obtained, the fact is described as the inspection data 133 in the RAM.
This is stored in the memory 103 (steps S35, S36).

If the problem of the nozzle assembly 220 is not eliminated by the cleaning, the cleaning is repeated (steps S35, S37, S38). However, if nozzle clogging is not eliminated even after performing the predetermined number of cleanings, it is determined that cleaning should not be performed, and the process proceeds to an abnormality handling process (steps S37 and S39).

FIG. 15 is a flowchart showing the flow of the operation in step S39. In the abnormality handling process, first, it is confirmed whether or not the abnormal state of the nozzle assembly 220 satisfies a predetermined warning condition (step S41). As the warning condition, for example, a condition that two or more nozzles 221 of the same color are clogged is used. Details of the warning condition will be described later.

If the abnormal condition satisfies the warning condition, a warning is issued from the three-dimensional printing apparatus 100 to the operator (step S42). For example, a warning is issued by emitting a sound from a speaker, turning on a warning lamp, or displaying a warning on the display 111 of the computer 11.

On the other hand, if the abnormality of the nozzle assembly 220 does not satisfy the warning condition, the control data for scanning and discharging the nozzle assembly 220 (nozzle head 22) under the abnormal condition is generated (step S43). ). After completion of the abnormality handling process, the control data includes inspection data 13 indicating an abnormal nozzle.
3 (or together with the inspection data 133) in the RAM 103 (step S36).

FIGS. 16 to 18 show the inspection unit 1 when the abnormality illustrated in FIG.
3D modeling apparatus 1 based on the control data generated by
FIG. 9 is a diagram for explaining an example of a scanning and discharging operation of the nozzle assembly 220 performed by 00. As shown in FIG.
Row L3 in column Y, row L5 in column M, row L6 in column C, and
When the nozzle 221 in the row L2 of the column W is clogged, the output of the color corresponding to the abnormal nozzle is not performed in each row in one main scan (scan in the Y direction).

Therefore, as shown in FIG. 17, the nozzle assembly 220 is moved by one line in the sub-scanning direction (X direction).
The nozzle assembly 220 is again scanned in the main scanning direction.
At this time, as shown in FIG.
Only the nozzle 221 adjacent to the side is activated, and a normal binder is applied to each row.

As described above, in the computer 11, when the nozzle assembly 220 has not been normalized by the cleaning, the abnormal nozzle uses another normal nozzle 221 of the same function at the position where the binder should discharge the binder. Control data for performing ejection is generated.

In FIG. 16 to FIG.
A portion to be applied in two main scans is used to discharge the binder in two main scans. In order to apply a proper binder in two main scans, for a nozzle row of the same color, there are no abnormal nozzles in both the row L1 and the row L6, and The condition that they are not adjacent can be generally defined. Therefore, to issue a warning in step S42 when a normal binder cannot be applied in two main scans, the above condition is used as a warning condition in step S41.

In order to issue a warning in step S42 only when a normal binder cannot be applied in three main scans, a warning condition is separately set. In order to issue a warning only when a binder of a specific color cannot be applied to the same area even if the main scanning is repeated many times, all nozzles 221 for any color are set as a warning condition. Is abnormal.

As described above, the warning condition is appropriately set based on how complicated operations are required for the three-dimensional printing apparatus 100 to perform proper modeling, and there is an abnormality that does not satisfy the warning condition. In this case, the computer 11 uses the nozzle assembly 220 (nozzle head 2) to apply a proper binder even when an abnormal nozzle exists.
The control data of 2) is required.

Of course, whether or not to issue a warning may simply be determined in accordance with the number of abnormal nozzles and the location of abnormal nozzles.

In FIG. 7 showing the molding operation of the three-dimensional molding apparatus 100, steps S25 and S28 show operations specific to the case where the three-dimensional molding apparatus 100 is molded in a state where an abnormal nozzle exists. When the binder is applied to the powder layer using the abnormal nozzle assembly 220 (step S24), it is confirmed whether or not the nozzle assembly 220 is normal by referring to the inspection data 133 (step S25). ).

If there is an abnormality in the nozzle assembly 220, the control signal generator 182 and the binder discharge controller 125 move the nozzle head 22 slightly in the sub-scanning direction in accordance with the control data obtained in advance by the computer 11. And re-scanning is performed (step S28). Thus, the binder is discharged from the normal nozzle 221 to the position where the abnormal nozzle should discharge the binder, and the appropriate three-dimensional structure 91 is generated using the nozzle assembly 220 having the abnormality. . That is, by providing a proper binder without missing dots, a three-dimensional structure 91 having normal strength is generated.

In FIG. 7, the inspection data 133 is referred to each time the binder is discharged to each powder layer. However, the inspection data 133 is referred each time one three-dimensional structure 91 is formed. May be performed.

As described above, the three-dimensional printing apparatus 1
In 00, inappropriate molding is prevented beforehand by detecting an abnormal nozzle. Then, as a countermeasure against the abnormal nozzle, the nozzle 221 is cleaned using the cleaning liquid, and even if an abnormal nozzle exists, the main scanning of the nozzle head 22 is repeated to achieve appropriate modeling.

FIG. 19 shows that the nozzle 22 is separate from the inspection operation.
6 is a flowchart showing an operation flow when cleaning is periodically performed in order to prevent clogging of No. 1;

When the power of the apparatus is turned on, a timer inside the computer 11 starts (step S51), and the operation shown in FIG. 19 is in a standby state until a predetermined time has elapsed (step S52). When the predetermined time has elapsed, it is confirmed whether or not the three-dimensional modeling apparatus 100 is performing a modeling operation (step S53). If the modeling is being performed, the three-dimensional modeling apparatus 100 is in a standby state until the modeling operation is completed.

If the modeling has not been performed or the modeling operation has been completed, a signal is sent from the computer 11 to the cleaning control unit 127, and the above-described cleaning operation is performed (step S54). Thereafter, the timer is reset (step S55), and the process returns to step S51. The above operation is repeated until the power of the three-dimensional printing apparatus 100 is turned off (step S56).

As described above, in the three-dimensional printing apparatus 100,
Apart from the abnormality detection operation of the nozzle 221, the nozzle cleaning is performed almost regularly. This prevents nozzle clogging. The cleaning of the nozzle 221 may be performed periodically regardless of whether or not the molding is being performed.

<4. Modifications> Although the three-dimensional printing apparatus 100 according to one embodiment of the present invention has been described above, the present invention is not limited to the above embodiment, and various modifications are possible.

In the above-described embodiment, the abnormality of the nozzle assembly 220 is detected by observing the binder discharged to the inspection area 83 by the scanner 25, but the abnormality is detected by another method. May be.

For example, the scanner 25 may be provided with a two-dimensional CCD, so that image data is taken in at one time. The pattern of the binder formed when the nozzle assembly 220 is inspected may be any pattern.

The binder is used for the inspection area 8 on the powder layer.
It is not necessary to discharge the binder toward the inspection area 3, and the binder may be discharged toward the inspection area outside the powder layer prepared in advance, and the discharged binder may be observed by the scanner 25.

The number of nozzles does not need to be plural, and only one nozzle 221 may be provided when the three-dimensional structure 91 in which coloring is not performed is generated.

In the above embodiment, the nozzle abnormality need not be detected in the inspection area 83 irrelevant to the molding. The nozzle abnormality can be detected by monitoring the discharge state of the binder while performing the molding. May be.

The nozzle 221 may be inspected by passing the discharged droplet of the binder between the light emitting element and the light receiving element of the transmission type optical sensor, and the droplet of the binder may be detected by the vibration detecting sensor. You may make it collide with a surface. Of course, the abnormality detection of the nozzle assembly 220 may be sequentially performed for each nozzle 221.

It is not necessary for the binder to be discharged by a nozzle which is clearly grasped as a nozzle, and any mechanism can be used as long as it is a three-dimensional molding apparatus for applying the binder to a target position of the powder layer. May be done.

The detected abnormality is not limited to nozzle clogging. For example, an abnormally large or small amount of discharged binder may be detected. That is, any abnormality may be detected as long as the abnormality is detected with respect to the application of the binder to the powder layer.

Various processes may be performed for cleaning the nozzle 221. For example, if the cleaning liquid
Alternatively, the nozzle 221 may be supplied from below (from the opening end side), or the tip of the nozzle 221 may be immersed in a cleaning liquid to which ultrasonic vibration has been applied.

The cleaning operation is not limited to the cleaning using the cleaning liquid, and a cleaning operation of rubbing the rubber member against the nozzle tip may be performed.

Further, the operation which cannot be regarded as cleaning is performed based on the result of the abnormality detection, whereby the nozzle 22
1 may be normalized (that is, restored). For example, nozzle clogging may be eliminated by repeating the binder discharging operation.

Further, in the above embodiment, it has been described that the cleaning is performed periodically, but the inspection and the cleaning may be performed periodically.

Further, the present invention can be used for any method of producing a three-dimensional structure while laminating powder. The powder layer may be formed by other methods such as a roller, and various binders and powders may be used.

For example, the binder may be a combination of a so-called adhesive and another material (for example, a commercially available paint), or an ordinary adhesive may be used as it is. That is, any material may be used as long as it has a binding action. A colorless and transparent binder may also be used. Even in this case, by detecting the reflection of light in the inspection area 83, it is possible to specify the area to which the binder has been applied.

The molding powder may be colorless, transparent or chromatic, and resins, metals, rubbers, biodegradable materials and the like may be used as the powder material.

Also, different from the above-described embodiment, the binder may be of one type, and the ink and the binder may be separately applied to the powder layer.

The powder layer does not need to be horizontal, and may be inclined as far as the layer can be formed.

If a CAD / CAM / CAE system is introduced into the computer 11 of the three-dimensional printing apparatus 100, it is possible to speed up the printing process and improve the quality of the design.

[0126]

According to the first to eleventh aspects of the present invention, it is possible to detect an abnormality with respect to the application of the bonding material by the application means, thereby preventing inappropriate molding.

According to the second aspect of the present invention, an abnormality can be detected by observing the bonding material applied to a predetermined area. According to the third and tenth aspects of the present invention, an abnormality included in a plurality of nozzles can be detected. The nozzle can be specified.

Further, according to the fourth and eleventh aspects of the present invention, appropriate molding can be realized even when an abnormal nozzle exists.

Further, according to the inventions of claims 5 and 6, when the abnormality of the applying means is detected, the restoration is performed to realize an appropriate molding, and in the invention of claim 7, a simple cleaning liquid is discharged. The operation can clean the nozzle.

Further, according to the eighth aspect of the present invention, it is possible to prevent occurrence of an abnormality in the applying means.

[Brief description of the drawings]

FIG. 1 is a diagram showing an overall configuration of a three-dimensional printing apparatus.

FIG. 2 is a diagram illustrating an internal configuration of a tank unit and a nozzle head, and a functional configuration of a drive control unit related to these configurations.

FIG. 3 is a diagram illustrating an internal configuration of a scanner.

FIG. 4 is a block diagram illustrating a configuration of a computer.

FIG. 5 is a block diagram illustrating a functional configuration of a computer.

FIG. 6 is a flowchart showing a flow of the operation of the three-dimensional printing apparatus.

FIG. 7 is a flowchart showing a flow of the operation of the three-dimensional printing apparatus.

FIGS. 8A to 8C are diagrams illustrating an example of a state of generation of cross-sectional data.

FIGS. 9A to 9C are diagrams showing how to generate other cross-sectional data (shape data).

FIGS. 10A to 10C are conceptual diagrams illustrating the operation of the three-dimensional printing apparatus.

FIG. 11 is a view showing a state of movement of a nozzle assembly.

FIG. 12 is a flowchart illustrating a flow of an inspection operation.

FIG. 13 is a diagram showing a discharge state of a binder by a normal nozzle assembly.

FIG. 14 is a diagram illustrating a discharge state of a binder when an abnormal nozzle exists.

FIG. 15 is a flowchart illustrating a flow of an abnormality handling process.

FIG. 16 is a diagram exemplifying a binder ejection state in a first main scan when an abnormal nozzle exists.

FIG. 17 is a diagram illustrating a state of movement of a nozzle assembly when an abnormal nozzle exists.

FIG. 18 is a diagram exemplifying a binder ejection state in a second main scan when an abnormal nozzle exists.

FIG. 19 is a flowchart showing a flow of an operation in periodic cleaning.

[Explanation of symbols]

Reference Signs List 20 binder applying unit 25 scanner 30 modeling unit 40 powder supply unit 50 powder diffusion unit 91 three-dimensional modeling device 100 three-dimensional modeling device 101 CPU 102 ROM 103 RAM 125 binder discharge control unit 126 inspection control unit 127 cleaning control unit 132 image data 182 Control signal generation unit 183 Inspection unit 212 Tank 220 Nozzle assembly 221 Nozzle 242 Channel switching unit S21 to S28, S31 to S34, S43, S51 to S
56 steps

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F213 AA36 AB16 AB19 AC04 WA25 WB01 WL03 WL12 WL32 WL43 WL67 WL85 WL87 WL92

Claims (11)

[Claims] 1. A three-dimensional modeling apparatus for generating a three-dimensional modeled object corresponding to a modeling object by applying a bonding material to a powdered material and bonding the powdered material, wherein the layers are formed by sequentially stacking layers of the powdered material. A layer forming unit, and applying a bonding material to the layer each time the layer forming unit forms a layer of the powder material, thereby corresponding to a cut surface obtained by cutting the modeling object by a plurality of parallel surfaces. A three-dimensional modeling apparatus comprising: an applying unit that sequentially forms a combined body of powder materials; and a detecting unit that detects an abnormality in applying the bonding material by the applying unit. 2. The three-dimensional printing apparatus according to claim 1, wherein the detection unit obtains an observation result by observing a bonding material applied to a predetermined area by the application unit; Means for judging a state of the applying means based on a result. 3. The three-dimensional printing apparatus according to claim 2, wherein the applying unit includes a plurality of nozzles for discharging a bonding material, and the determining unit determines the plurality of nozzles based on the observation result. A three-dimensional modeling apparatus characterized by identifying an abnormal nozzle included in a three-dimensional object. 4. The three-dimensional modeling apparatus according to claim 3, wherein the specified abnormal nozzle discharges the bonding material from another normal nozzle to a position where the bonding material should discharge the bonding material. A three-dimensional printing apparatus further provided. 5. The three-dimensional printing apparatus according to claim 1, further comprising a recovery unit that recovers the adding unit when the abnormality is detected by the detection unit. 3D modeling equipment. 6. The three-dimensional modeling apparatus according to claim 5, wherein the restoration unit cleans the applying unit using a cleaning liquid. 7. The three-dimensional printing apparatus according to claim 6, wherein the applying means has a nozzle for discharging a bonding material, and the restoring means supplies a cleaning liquid to the nozzle to discharge the cleaning liquid. A three-dimensional printing apparatus characterized by the following. 8. The three-dimensional modeling apparatus according to claim 6, wherein the recovery means periodically cleans the applying means. 9. A three-dimensional modeling method for generating a three-dimensional modeled object corresponding to a modeling target object by applying a bonding material to a powder material and bonding the powdered material, wherein: (a) forming a layer of the powdered material; (B) applying a bonding material to the layer using an application unit to form a composite of a powder material corresponding to a cut surface obtained by cutting the modeling object on one surface; (c) By repeating the steps (a) and (b), the three-dimensional object is formed by sequentially laminating a combination of powdered materials corresponding to cut surfaces obtained by cutting the object on a plurality of parallel surfaces. A three-dimensional modeling method, comprising: a generating step; and (d) a step of detecting, by a detecting unit, an abnormality in applying the bonding material by the applying unit. 10. The three-dimensional modeling method according to claim 9, wherein the applying means has a plurality of nozzles for discharging a bonding material, and the step (d) includes: Discharging the bonding material from the nozzle toward a predetermined region; and (d-2) identifying abnormal nozzles included in the plurality of nozzles by observing the bonding material discharged to the predetermined region. And a three-dimensional molding method. 11. The three-dimensional modeling method according to claim 10, wherein when the abnormal nozzle is specified in the step (d-2), the abnormal nozzle discharges the bonding material in the step (a). A three-dimensional printing method characterized by discharging a bonding material from another normal nozzle to a position to be formed.