JP2014088046A - Molding method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding method in which a powder-containing layer is coated with a binding liquid, and curing is performed to mold a molded object, where the infiltration of the binding liquid to a lower layer upon the forming of a bulged part is suppressed.SOLUTION: In the case where the molding part 22b of a slurry layer 21b has a bulged part 24b bulged to a direction orthogonal to a lamination direction to the molding part 22a of a slurry layer 21a, in the binding step of the slurry layer 21a, a UV ink I is applied to a region superimposed on the bulged part 24b to cure the UV ink I, and a ground layer 25a having a film thickness smaller than that of molding part 22a is formed.

Description

  The present invention relates to a modeling method for forming a modeled object by stacking layers composed of particles bound via a binding liquid.

  Conventionally, an additive manufacturing method is frequently used as a method (rapid prototyping) of a prototype quickly. In the additive manufacturing method, after a model of a three-dimensional CAD model is divided into a number of two-dimensional cross-sectional layers, a layered structure corresponding to each two-dimensional cross-sectional layer is sequentially formed and stacked to form a three-dimensional object. To do. Specifically, for example, as described in Patent Document 1, first, particles including ceramic, metal, or the like are formed in layers. Next, a binding liquid for binding the particles to each other in a part of the layer made of the particles is discharged to the layer made of the particles by, for example, an ink jet type droplet discharge device. Then, the binding liquid that has permeated into the gaps between the particles binds the particles together with hardening thereof, thereby forming a layered structure corresponding to the two-dimensional cross-sectional layer. Thereafter, similarly, formation of a layer made of these particles and discharge of the binding liquid are alternately repeated to form a shaped article.

Japanese Patent No. 2729110

  By the way, in the modeling object of the modeling method described above, a projecting portion that projects in a direction perpendicular to the stacking direction from the layered structure in the k-th layer (k is an integer of 1 or more) is layered in the (k + 1) -th layer. Some are in the structure. In the (k + 1) th layer, the binding liquid is discharged to the portion that becomes the overhanging portion, but the discharged binding liquid may permeate to the kth layer. If the (k + 1) -th layer binding liquid is cured in this state, the overhanging portion becomes thick by the amount permeated into the k-th layer, and the accuracy of the shape of the overhanging portion, and consequently the shaped article, is lowered. Moreover, the amount of the binding liquid applied to the portion that becomes the layered structure is determined in advance by the mechanical strength based on the design rule. Therefore, if the binding liquid penetrates to the k-th layer as described above, the density of the binding liquid in the portion that becomes the overhanging portion will be reduced, and thereby, between the granules after curing The binding force of the sheet becomes weak, and the mechanical strength of the overhanging portion is lowered.

  These problems are not limited to the layered manufacturing method using the droplet discharge device, but are generally common to methods for modeling a modeled object by applying a binding liquid to a layer made of granules. It is.

  The present invention has been made in view of such a situation, and its purpose is to form a projecting portion in a modeling method for modeling a modeled object by applying a binding liquid to a layer containing particles and curing it. It is in providing the modeling method which suppresses the penetration | invasion of the binding liquid to the lower layer in.

  The modeling method of the present invention includes a layer forming step for forming a layer including particles, and the particles are bonded by curing the binding solution after infiltrating a part of the layer with the binding solution. A binding step of forming the layered structure on the layer, and a removal step of removing a portion other than the layered structure from the layer including the layered structure, the layer forming step and the binding step; Are alternately formed to form a laminate composed of the layers, and then the removal step is performed to form a modeled object in which the layered structure is laminated, ) When the layered structure of the layer (k is an integer of 1 or more) has a projecting portion that projects in a direction perpendicular to the stacking direction with respect to the layered structure of the kth layer, the connection of the kth layer In the attaching step, the binding liquid is formed in a region overlapping the overhanging portion. Applied to cure the the binder solution to form small underlayer film thickness than the layered structure.

  According to the modeling method of the present invention, the base layer of the overhanging portion in the (k + 1) th layer is formed in the k-th layer binding step. With such a configuration, even if the binding liquid applied in the (k + 1) -th layer binding step attempts to penetrate into the k-th layer, the penetration is suppressed by the base layer obtained by curing the binding liquid. Therefore, compared to the case where the binding liquid penetrates into the k-th layer, not only can the shape of the overhanging part be realized with high accuracy, but also the decrease in the density of the binding liquid in the overhanging part can be suppressed. Therefore, it is possible to suppress a decrease in mechanical strength of the overhanging portion. In addition, the contact area between the k-th layered structure and the (k + 1) -th layered structure can be increased as compared with the case where the k-th layered structure does not include an underlayer. . Thereby, the adhesion between the k-th layered structure and the (k + 1) -th layered structure can also be improved. Therefore, not only the overhanging portion, but also the mechanical strength of the shaped object in which such layered structures are laminated can be increased.

In this modeling method, the base layer may be formed over the entire region overlapping the overhanging portion.
According to this modeling method, the base layer in the k-th layer and the overhanging portion in the (k + 1) -th layer are in contact over the entire area of the overhanging portion. That is, since the contact area between the base layer and the overhanging portion is maximized, the adhesion between the k-th layered structure and the (k + 1) th layered structure can be further enhanced.

In this modeling method, the base layer may be formed in a part of a region overlapping the overhanging portion.
According to this modeling method, the base layer in the kth layer and the overhanging portion in the (k + 1) th layer are in contact with each other at a part of the overhanging portion. In such a configuration, the underlayer is formed in a state of being separated from each other. However, due to the affinity between the binding liquid and the underlayer that is obtained by curing the binding liquid, the (k + 1) th layer is formed. Permeation of the binding liquid applied to the k-th layer is suppressed. Also, with such a configuration, the accuracy of the average thickness at the overhanging portion can be increased as compared with the case where the underlayer and the overhanging portion are in contact with each other over the entire area.

In this modeling method, in the k-th layer binding step, a binding solution for forming the layered structure and the base layer is continuously applied.
Here, for example, if the base layer is formed after forming the layered structure in the k-th layer binding step, the coating and curing of the binding solution are repeatedly performed when one layer is formed. Therefore, there is a concern that the productivity of the modeled product is lowered. In this respect, according to this modeling method, since the binding liquid for forming the layered structure and the base layer is continuously applied, the binding liquid of the layered structure and the base layer is cured at the same timing. be able to. As a result, even if an underlayer is formed in addition to the layered structure, it is possible to suppress a decrease in the productivity of the shaped object. Further, when the base layer is formed in the entire region overlapping with the projecting portion, for example, if the base layer is formed after forming the layer structure in the k-th layer binding step, the layer structure and the lower layer are formed. A boundary is formed between the basement layer and these become separate parts, so that the adhesion between the layered structure and the underlying layer may be reduced. In this respect, according to this modeling method, since the layered structure and the underlayer are integrally formed, the adhesion between the layered structure and the underlayer can be improved.

  In this modeling method, the layer is formed from a slurry containing hydrophobic particles, an aqueous solvent, and an amphiphilic solid polymer dissolved in the aqueous solvent, and an aqueous liquid is allowed to flow in the removing step. Thus, it is preferable to remove a portion other than the layered structure from the laminate.

  According to this modeling method, a slurry in which hydrophobic particles are suspended in an aqueous solvent is used as a material for forming a layer. For this reason, even if vibration is given to the slurry during formation of the modeled object, the hydrophobic particles are held in the aqueous solvent, so that scattering of the particles is suppressed. In addition, since the aqueous solvent is used as a solvent for suppressing the scattering of the particles, the particles are dissolved in the solvent, or the particles are swollen by absorbing the solvent. The body can be prevented from being denatured. Furthermore, an amphiphilic solid polymer is added as a constituent material of the slurry. Such an amphiphilic solid polymer has affinity with the hydrophobic particles at the hydrophobic site and has affinity with the aqueous solvent at the hydrophilic site. Therefore, the hydrophobic particles can be uniformly dispersed in the aqueous solvent through the amphiphilic solid polymer. Therefore, in a model formed using such modeling slurry, hydrophobic particles that are the forming material are uniformly present.

  And in the said modeling method, the unbound area | region is removed from a laminated body with an aqueous liquid. At this time, since the slurry constituting the layer includes an aqueous solvent and an amphiphilic solid polymer, the unbound region can be easily removed with an aqueous liquid.

In this modeling method, it is preferable that the binding liquid for forming the base layer is applied by an ink jet method.
By applying the binding liquid using the inkjet method as in this modeling method, the position and amount of the binding liquid for forming the underlayer can be changed in units of droplets. . Therefore, it is possible to improve the degree of freedom regarding the formation position and thickness of the base layer, whether the binding liquid is applied to a part of the region overlapping with the overhanging portion or the entire region.

The flowchart which shows the procedure of the modeling method which concerns on one embodiment of this invention. (A) (b) (c) The figure which shows typically each process of the modeling method along a procedure. (A) (b) (c) The figure which shows typically each process of the modeling method along a procedure. The figure which shows typically the 1st layer after application | coating of a binding liquid. Sectional drawing which shows the cross-section of a molded article. The figure which shows typically the 1st layer after application | coating of a binding liquid in a modification.

Hereinafter, an embodiment of a modeling method according to the present invention will be described with reference to FIGS.
First, the procedure of the modeling method in the present embodiment will be described. FIG. 1 is a flowchart showing a procedure of a modeling method according to an embodiment of the present invention. As shown in FIG. 1, in this modeling method, first, a sacrificial layer forming step (step S11) using a modeling slurry is performed. Next, a slurry layer forming step (step S12) using the modeling slurry, an ultraviolet curable resin dropping step (step S13), and an ultraviolet irradiation step (step S14) are repeatedly performed. And a support material removal process (step S15) is implemented.

  Next, the composition of the molding slurry used in the above-described modeling method will be described. The slurry for modeling used in the present embodiment is a suspension in which three materials, a hydrophobic particle, an aqueous solvent, and an amphiphilic solid polymer are kneaded.

  The hydrophobic particles are a main constituent material of a modeled object formed using a modeling slurry. As the hydrophobic particles, hydrophobic resin particles such as acrylic resin powder, silicone resin powder, acrylic silicone resin powder, polyethylene resin powder, and polyethylene acrylic acid copolymer resin powder can be used. In addition, the hydrophobic particle | grains in this Embodiment are the particle | grains which do not melt | dissolve 1g or more with respect to 100g of aqueous solvents.

  With respect to the aqueous solvent, the solubility of the hydrophobic particles constituting the modeled object is low as described above. Therefore, it is difficult for the hydrophobic particles to be modified due to dissolution in the solvent or absorption of the solvent. Therefore, it is preferable as a medium for suppressing scattering of hydrophobic particles. The aqueous solvent includes water and a non-organic solvent such as an aqueous solution of an inorganic salt. Of these, water is preferably used as the aqueous solvent. Further, the aqueous solvent may be one obtained by adding a water-soluble organic solvent to water.

  The amphiphilic solid polymer is a material that forms a shaped object together with the hydrophobic particles. Since this solid polymer is amphiphilic, it dissolves in the aqueous solvent due to the affinity with the aqueous solvent due to the hydrophilic portion, and the hydrophobic particles due to the affinity with the hydrophobic particles due to the hydrophobic portion. Disperses the body in a solvent. As the amphiphilic solid polymer, a material having a hydrocarbon chain as a main chain and a hydrophilic functional group as a side chain can be used. Among them, it is preferable to use polyvinyl alcohol which has a straight hydrocarbon chain but has higher hydrophilicity than other materials.

  In the slurry in which the above three materials are kneaded, the hydrophobic particles of the amphiphilic solid polymer are also in a state where the hydrophobic particles are cross-linked with each other. Therefore, even when vibrations are applied to the slurry during formation of the shaped object, the hydrophobic particles are retained in the structure formed by cross-linking between the particles, so that the scattering of the particles is suppressed. Will come to be.

  In addition, the hydrophobic particles are uniformly dispersed in the aqueous solvent through the hydrophilic portion of the amphiphilic solid polymer that interacts in the hydrophobic portion. Therefore, in the molded object formed using such a slurry, the hydrophobic particles as the forming material are present uniformly. In addition, since these amphiphilic solid polymers are themselves a material for forming a shaped object, it is necessary to remove the amphiphilic solid polymer during or after the formation of the shaped object. And not.

Next, the modeling method using the slurry having the above composition will be described in more detail with reference to FIGS. 2 and 3 schematically show processing performed in each of the above steps.
As shown in FIG. 1, in this modeling method, first, in a sacrificial layer forming step (step S11: FIG. 2A), for example, on a substrate 11 (base) such as a glass substrate or a plastic sheet, The sacrificial layer 12 is formed as the lowermost layer of the slurry layer by applying the slurry so that the thickness is 200 μm. For applying the slurry, a known method such as a squeegee method, a screen printing method, a doctor blade method, and a spin coating method can form a slurry layer having a substantially uniform thickness on the substrate 11. Can be used.

  Next, in the slurry layer forming step (step S12: FIG. 2B), the slurry is applied to form a first slurry layer 21a so as to have a thickness of 100 μm. It should be noted that the above-described known method can be used for forming the slurry layer 21a as well as the formation of the sacrificial layer 12.

  Then, in the ultraviolet curable resin dropping step (step S13: FIG. 2C), the droplet discharge device 31 is formed on the modeling portion 22a for forming a part of the modeling object 20 (FIG. 3) in the slurry layer 21a. And UV ink I containing an ultraviolet curable resin as a binding liquid is ejected by an ink jet method. Here, in the slurry layer 21a, the hydrophobic particles are cross-linked by the polyvinyl alcohol, so that the hydrophobic particles are arranged with a predetermined space between each other. Is filled with water. Therefore, the UV ink I ejected from above the slurry layer 21a toward the surface of the slurry layer 21a reaches the back surface of the slurry layer 21a through the above-described space. That is, since the UV ink I permeates the entire modeling portion 22a, the strength of the modeling portion 22a is improved. Incidentally, since the hydrophobic region in the polyvinyl alcohol in the slurry layer 21a has affinity for the UV ink I, the UV ink I can easily penetrate into the slurry layer 21a.

  The UV ink I includes a cationic polymerization type ultraviolet curable resin that cures by a polymerization reaction using a cation as an active species, and a radical polymerization type ultraviolet curable resin that cures by a polymerization reaction using a radical as an active species. There is a thing. In the present embodiment, any of these UV inks I can be used. However, the UV ink I is dropped onto the modeling portion 22a of the slurry layer 21a and then cured together with the hydrophobic particles included in the modeling portion 22a. Therefore, it is preferable to select compatible materials for the UV ink I, particularly the ultraviolet curable resin and the hydrophobic particles. That is, it is preferable to use the same material for the UV ink I and the hydrophobic particles, for example, the acrylic UV ink I and the acrylic resin powder. Alternatively, it is preferable to use UV ink I and hydrophobic particles having a material similar to UV ink I introduced on the surface, for example, acrylic UV ink I and acrylic silicone resin powder. That is, here, the same system means that the main skeleton of the repeating unit structure constituting the hydrophobic particles and the main skeleton of the unit structure of the resin contained in the UV ink I are the same. In addition, the same system is different in the side chain functional group in the unit structure and part of the main skeleton in the unit structure, but the interaction between the hydrophobic liquid and the resin is substantially the same as the interaction between the hydrophobic particles. This means that the main skeletons of the unit structure partially overlap each other. Therefore, when each of the hydrophobic particles and the resin is a copolymer, those in which the composition ratios of the atoms contained in these particles are not the same are assumed to be the same system.

  Thereafter, in the ultraviolet irradiation process (step S14: FIG. 3 (a)), the ultraviolet L is irradiated onto the entire slurry layer 21a, whereby the UV ink I contained in the modeling portion 22a is cured and the particles are formed. It binds via UV ink I. Note that the ultraviolet light L does not have to be irradiated to the entire slurry layer 21a, and it is sufficient to irradiate at least the modeling portion 22a of the slurry layer 21a. Further, the irradiation of the ultraviolet light L can be performed alternately with the dropping of the UV ink I onto the modeling portion 22a by, for example, the ultraviolet irradiation device mounted on the droplet discharging device 31, and the droplet discharging device. This can be performed for each slurry layer by an ultraviolet irradiation device provided separately from 31.

  By the dropping of the UV ink I and the irradiation of the ultraviolet rays L as described above, a shaped part 22a in which the particles are bound to each other is formed, and this shaped part 22a constitutes a part of the shaped object 20. On the other hand, areas other than the modeling part 22a in the slurry layer 21a are formed in the modeling part 22a formed in the same slurry layer 21a, the second slurry layer 21b which is the next layer of the slurry layer 21a, and the like. It functions as a support portion 23a that mechanically supports the modeling portion 22b and the like. Thereby, for example, as shown in FIG. 3B, the modeled object 20 is formed that has an overhanging portion 24 b in which the upper layered portion 22 b protrudes in a direction perpendicular to the stacking direction from the lower layered portion 22 a. Even if it does, it is not necessary to form the support part which supports the overhang | projection part 24b separately. Moreover, since the formation 20 is formed in a state where the slurry layer is present in the lower layer of the overhanging portion 24b, it is possible to suppress the protrusion from being lost during the formation of the formation 20. The binding step is composed of the ultraviolet curable resin dropping step and the ultraviolet irradiation step.

  The three processes from the slurry layer forming process (step S12) to the ultraviolet irradiation process (step S14) are repeatedly performed until all of the modeling parts constituting the modeled article 20 are formed. For example, as shown in FIG. 3B, when the modeled object 20 is composed of five slurry layers 21a, 21b, 21c, 21d, and 21e, the above three steps are repeated five times in order. Thus, since the laminated body comprised from a some layer can be formed by repeating 4 processes from a layer formation process to an ultraviolet irradiation process in order, the shape of the molded article 20 formed by the said modeling method The degree of freedom related to increases.

  When all the modeling parts 22a, 22b, 22c, 22d, and 22e constituting the modeled article 20 are formed, the slurry layers 21a, 21b, 21c, and 21d are formed in the support part removing step (step S15: FIG. 3C). , 21e, the support portions 23a, 23c, 23d, and 23e are removed. The support portions 23a, 23c, 23d, and 23e can be removed by immersing the laminate together with the substrate 11 in an aqueous liquid, for example, water, or spraying water on the laminate at a predetermined pressure.

  In addition, the water used for the support part removal process includes the hydrophobic particles constituting the support parts 23a, 23c, 23d, and 23e. As described above, since the hydrophobic particles constituting the support portions 23a, 23c, 23d, and 23e are difficult to dissolve in water, the hydrophobic particles can be extracted by filtering the water. That is, you may make it perform the extraction process of a hydrophobic particle following the said support part removal process. The hydrophobic particles extracted in this way can be reused as a constituent material of the slurry.

  Here, the modeled part 22b of the modeled article 20 described above has a projecting part 24b that projects in a direction perpendicular to the stacking direction with respect to the modeled part 22a formed using the slurry layer 21a that is the immediately preceding layer. ing. The portion of the slurry layer 21b which becomes the overhanging portion 24b is mechanically supported by the support portion 23a formed on the slurry layer 21a, that is, the modeling slurry to which the UV ink I is not applied in the slurry layer 21a. That is, the slurry layer 21b and the support portion 23a are connected to each other by the above-described modeling slurry, although there is a difference in the evaporation degree of the aqueous solvent. Therefore, when the UV ink I applied to form the overhanging portion 24b reaches the back surface of the slurry layer 21b (the contact surface with the slurry layer 21a), it may penetrate into the support portion 23a. Then, if the UV ink I is cured in a state where it penetrates into the support portion 23a, the overhang portion 24b is thickened by the amount permeated into the support portion 23a, so that the shape of the overhang portion 24b and eventually the shaped article 20 is increased. Accuracy will be reduced.

  Further, the amount of UV ink I applied to form the modeling portion 22b is determined in advance by mechanical strength based on the design rule. Therefore, as described above, if a part of the UV ink I penetrates into the support portion 23a, the density of the UV ink I in the portion that becomes the overhanging portion 24b decreases. As a result, even if the UV ink I is cured, the binding force between the particles is weakened, so that the mechanical strength in the overhanging portion 24b is lowered.

  Therefore, in the modeling method according to the present embodiment, the support portion 23a has the overhanging portion 24b in order to prevent a part of the UV ink I applied to form the overhanging portion 24b from penetrating into the support portion 23a. The underlayer 25a is formed. That is, the layered structure in the slurry layer 21a is configured by the modeling portion 22a and the base layer 25a having a smaller film thickness than the modeling portion 22a.

  FIG. 4 is a diagram schematically showing the first layer after the binding liquid is applied, and is a sectional view schematically showing a sectional structure in the slurry layer 21a. FIG. 5 is a cross-sectional view illustrating a cross-sectional structure of a modeled object, and is an enlarged cross-sectional view illustrating an enlarged joint portion between the modeled portion 22a and the overhang portion 24b.

  As shown in FIG. 4, UV ink I is continuously discharged onto the slurry layer 21 a by using the droplet discharge device 31 to the modeling portion 22 a and the entire region overlapping the overhanging portion 24 b. The discharge of the UV ink I by the droplet discharge device 31 is performed based on discharge data that defines information related to the discharge of the UV ink I in the slurry layer 21a. The ejection data is data that is generated in advance based on the cross-sectional data of the shaped article 20, for example, and is data that defines the ejection position of the UV ink I, the number of ejections at that position, and the like. And the modeling part 22a and the foundation | substrate layer 25a are integrally formed by irradiating the ultraviolet-ray L to the slurry layer 21a. For this reason, the part which becomes the overhang | projection part 24b in the slurry layer 21b is supported by the support part 23a in the form where the base layer 25a intervened. It should be noted that the amount of UV ink I applied in the region that overlaps the overhanging portion 24b is an amount that penetrates only into the surface layer of the slurry layer 21a, and is much smaller than the UV ink I applied to form the modeling portion 22a. Amount.

With such a configuration, even if the UV ink I for forming the overhanging portion 24b tries to permeate the support portion 23a, the UV ink I can be blocked by the underlying layer 25a. As a result, the overhanging portion 24b becomes thicker by the thickness of the base layer 25a, but the UV ink I for forming the overhanging portion 24b penetrates the support portion 23a more than in the case where the overhanging portion 24b The accuracy of the shape can be increased and the density drop of the UV ink I can be suppressed. Therefore, by forming the base layer 25a in the slurry layer 21a, it is possible to realize the shape of the overhanging portion 24b and, consequently, the shaped article 20 with high accuracy, and to suppress the reduction in mechanical strength. Moreover, as shown in FIG. 5, by forming the foundation layer 25a in the slurry layer 21a, the layered structure of the slurry layer 21a composed of the modeling portion 22a and the foundation layer 25a and the slurry layer 21b having the overhanging portion 24b are formed. Since the contact area with the layered structure is increased, it is possible to improve the adhesion.
(A) Hydrophobic particles Charine R-170S (particle size 30 μm) (manufactured by Nissin Chemical Industry Co., Ltd.) (Charine: registered trademark)
-(B) Aqueous solvent water-(C) Amphiphilic solid polymer POVAL JP-03 (manufactured by Nippon Vinegar-Poval Co., Ltd.)
Composition ratio (A) :( B) :( C) = 7: 3.1: 0.22 (unit: g)
・ Thickness of each slurry layer 100μm
-UV ink Acrylic UV ink As described above, according to the modeling method according to the present embodiment, the effects listed below can be obtained.

  (1) The slurry layer 21a was coated with UV ink I over the entire region overlapping the overhanging portion 24b, and a base layer 25a was formed by curing this. With such a configuration, it is possible to prevent a part of the UV ink I applied to form the protruding portion 24b in the slurry layer 21b from penetrating into the support portion 23a. Thereby, the shape of the overhang | projection part 24b and by extension, the molded article 20 is realizable with high precision.

(2) Moreover, since the density fall of the UV ink I in the overhang | projection part 24b is suppressed, the fall of the mechanical strength of the overhang | projection part 24b and by extension, the molded article 20 can be suppressed.
(3) Further, since the contact area between the layered structure of the slurry layer 21a composed of the modeling portion 22a and the base layer 25a and the layered structure of the slurry layer 21b having the overhanging portion 24b is increased, these adhesive properties are increased. It can also be improved.

  (4) Here, it is possible to form the foundation layer 25a after forming the modeling part 22a on the slurry layer 21a, that is, to cure the modeling part 22a and the foundation layer 25a at different timings. However, if the application of the UV ink I and the irradiation with the ultraviolet light L are repeatedly performed when forming the layered structure in the slurry layer 21a, not only the productivity of the modeled object 20 may be lowered, but also the modeling A boundary is formed between the portion 22a and the base layer 25a, and this boundary may reduce the adhesion between the modeling portion 22a and the base layer 25a.

  In this regard, according to the above-described modeling method, the UV ink I is continuously applied to the slurry layer 21a over the modeling part 22a and the entire region overlapping the overhanging part 24b, thereby forming the modeling part 22a and the foundation layer 25a. Are integrally formed. With such a configuration, the application of the UV ink I and the irradiation of the ultraviolet light L in the slurry layer 21a only need to be performed once, and the modeling portion 22a and the base layer 25a function as one part so that these adhesive properties can be obtained. Can also be improved.

  (5) The modeling slurry is composed of water, which is an aqueous solvent, resin particles, which are hydrophobic particles, and polyvinyl alcohol, which is an amphiphilic solid polymer. Thereby, the resin particles are not in an independent state, but are in a state of being crosslinked with each other through the intervention of polyvinyl alcohol. Therefore, even when vibration or the like is given to the slurry layer during formation of the shaped article 20, since the resin particles are held in the structure formed by cross-linking between the particles, the scattering of the particles is suppressed. Will come to be.

  (6) UV ink I for forming the base layer 25a was applied using an inkjet method. In the ink jet method, the discharge position and the discharge amount can be changed in units of droplets. Therefore, regarding the application of the UV ink I for forming the base layer 25a, it is possible to change the application position and the application amount in units of droplets. Therefore, the degree of freedom regarding the formation position and thickness of the underlayer 25a can be improved.

It should be noted that the above embodiment can be implemented with appropriate modifications as follows.
The UV ink I was applied to the slurry layers 21a, 21b, 21c, 21d, and 21e by an ink jet method using the droplet discharge device 31. The present invention is not limited to this, and the UV ink I may be applied to the slurry layers 21a, 21b, 21c, 21d, and 21e using other methods such as a method using a mask in which the application position of the UV ink I is defined. .

  The above modeling method is not limited to the case of using the above modeling slurry, and it is repeated to form a layer composed of particles, apply UV ink I to the layer, and bind the particles together If it is with respect to the modeling method which forms a modeling object by, it can employ | adopt. In addition, when the layer comprised from a granule is formed, in a removal process, it is possible to remove parts other than a layered structure by spraying air on a laminated body, for example.

  In the binding step of the slurry layer 21a, the modeling portion 22a and the base layer 25a are integrally formed by performing the ultraviolet curable resin dropping step and the ultraviolet irradiation step related to the modeling portion 22a and the base layer 25a at the same time. By changing this, the ultraviolet curable resin dropping step and the ultraviolet irradiation step related to the modeling portion 22a may be performed at a different time from that related to the base layer 25a. That is, for example, after the ultraviolet curable resin related to the modeling portion 22a is discharged and cured, the ultraviolet curable resin related to the modeling portion 22a may be discharged and cured.

  In the above embodiment, the UV ink I is applied over the entire region overlapping the overhanging portion 24b. By changing this, for example, as shown in FIG. 6, UV ink I may be applied to a part of the region overlapping the overhanging portion 24b. In such a configuration, the base layer 25a is formed in a state of being separated from each other, but the base layer 25a obtained by curing the UV ink I has a high affinity for the UV ink I. Therefore, a part of the UV ink I which is about to penetrate into the slurry layer 21a comes into contact with the base layer 25a and is held by the base layer 25a. Therefore, the penetration of the UV ink I into the slurry layer 21a can be suppressed. Moreover, the average thickness of the overhanging portion 24b is superior to the case where the base layer 25a is formed over the entire region overlapping the overhanging portion 24b.

The binding liquid is not limited to the UV ink I containing an ultraviolet curable resin, but can be embodied in a liquid material containing a thermosetting resin.
The UV ink I was dropped on the modeling portions 22a, 22b, 22c, 22d, and 22e of the slurry layers 21a, 21b, 21c, 21d, and 21e, and then the ultraviolet ray L was irradiated. However, the present invention is not limited to this. For example, when the entire layer becomes the modeling portion 22b as in the slurry layer 21b, the modeling portion 22b may be formed only by the UV ink I without forming the slurry layer 21b. .

  The sacrificial layer 12 is formed on the substrate 11 prior to the formation of the slurry layers 21a, 21b, 21c, 21d, and 21e constituting the modeled object 20, but the sacrificial layer 12 may not be formed. .

  -Modeled object 20 illustrated what was formed by five layers of slurry layers 21a, 21b, 21c, 21d, and 21e. Not only this but the number of the layers which comprise the molded article 20 can be made into arbitrary numbers 2 or more. Moreover, the shape of the structure formed in each slurry layer is also arbitrary.

  I ... UV ink, L ... UV, 11 ... substrate, 12 ... sacrificial layer, 20 ... model, 21a, 21b, 21c, 21d, 21e ... slurry layer, 22a, 22b, 22c, 22d, 22e ... modeling unit, 23a , 23c, 23d, 23e ... support part, 24b ... overhang part, 25a ... underlayer, 31 ... droplet discharge device.

The modeling method of the present invention includes a layer forming step for forming a layer including particles, and the particles are bonded by curing the binding solution after infiltrating a part of the layer with the binding solution. wearing the layered structure comprises a binder forming the layer, by to repeat the said cohesion stage and the layer forming step alternately shaped object in the form of a laminate of the layered structure Is a modeling method in which the layered structure has a modeling part in which the binding liquid that has penetrated from the surface of the layer to which the binding liquid is applied to the back surface of the surface is cured, When the modeling part of the (k + 1) -th (k is an integer of 1 or more) layer has an overhanging part protruding in a direction perpendicular to the stacking direction with respect to the modeling part of the k-th layer, the k-th layer The binding step is a layered structure composed of the shaped part and the base layer that does not reach the back surface. Forming a first (k + 1) th layer of the binder process forms the protruding portion in a region overlapping the underlying layer.

In this modeling method, in the k-th layer binding step, a binding liquid for forming the k-th layer modeling portion and the base layer is continuously applied.
Here, for example, if the base layer is formed after forming the modeling part in the k-th layer binding step, the application and curing of the binding liquid are repeatedly performed when one layer is formed. Therefore, there is a concern that the productivity of the modeled product is lowered. In this respect, according to this modeling method, since the binding liquid for forming the modeling part and the base layer is continuously applied, the binding liquid of the modeling part and the base layer can be cured at the same timing. it can. As a result, even if the base layer is formed in addition to the modeling part , it is possible to suppress a decrease in the productivity of the modeled object. In addition, when the base layer is formed in the entire region that overlaps the overhanging portion, for example, if the base layer is formed after forming the modeling portion in the k-th layer binding step, the modeling portion and the base layer There is a possibility that the boundary between the formed part and the underlying layer may be lowered due to the formation of a boundary between them and the separate parts. In this respect, according to this modeling method, since the modeling part and the base layer are integrally formed, the adhesion between the modeling part and the base layer can be improved.

The modeling how, the further includes a removal step of removing the portion other than the layered structure of a laminate obtained by laminating the layer containing the layered structure, and a hydrophobic granules, and an aqueous solvent, a water-based solvent Preferably, the layer is formed from a slurry containing a dissolved amphiphilic solid polymer, and in the removing step, a portion other than the layered structure is removed from the laminate by flowing an aqueous liquid.

Claims (6)

A layer forming step of forming a layer containing particles;
A binding step of forming a layered structure in which the particles are bound to each other by curing the binding liquid after infiltrating a part of the layer with the binding liquid;
Removing a portion other than the layered structure from the layer including the layered structure, and repeating the layer forming step and the binding step alternately to form a laminate composed of the layers By performing the removing step, a modeling method in which a modeled object in the form of laminating the layered structure is modeled,
When the (k + 1) -th layered structure (k is an integer of 1 or more) has a projecting portion that projects in a direction perpendicular to the stacking direction with respect to the k-th layered structure, the k-th layer In the binding step of the eyes, the binding liquid is applied to a region overlapping the overhanging portion, and the binding liquid is cured to form a base layer having a thickness smaller than that of the layered structure. Modeling method. The modeling method according to claim 1, wherein the foundation layer is formed over the entire region overlapping the projecting portion. The modeling method according to claim 1, wherein the base layer is formed in a part of a region overlapping the overhanging portion. 4. The binding process for forming the layered structure and the base layer is continuously applied in the k-th layer binding step. 5. Modeling method. Forming the layer from a slurry comprising hydrophobic granules, an aqueous solvent, and an amphiphilic solid polymer dissolved in the aqueous solvent;
The modeling method according to any one of claims 1 to 4, wherein in the removing step, a portion other than the layered structure is removed from the laminated body by flowing an aqueous liquid. The modeling method according to claim 1, wherein a binding liquid for forming the base layer is applied by an inkjet method.

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