JP2015139957A - Three-dimensional modeling apparatus and three-dimensional modeling method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a three-dimensional modeling apparatus and a three-dimensional modeling method capable of modeling a three-dimensional object having a surface roughness which a user desires.SOLUTION: A three-dimensional modeling apparatus 100 comprises: a model material region formation unit (e.g., first discharge head 122, etc.) for discharging a model material to form a model material region 210; a support material region formation unit (e.g., second discharge head 124, etc.) for discharging a support material to form a support material region 220; a light source 126 for applying light energy to cure the support material region 220 after the support material region 220 is formed and before the model material region is formed; and a control unit 110 for adjusting the mixing ratio of the model material to the support material in the interface part 230 between the model material region 210 and the support material region 220, by changing the quantity of the light energy when the model material region 210 is formed.

Description

  The present invention relates to a three-dimensional modeling apparatus and a three-dimensional modeling method.

  A technique called rapid prototyping (RP) is known as a technique for modeling a three-dimensional solid object (hereinafter, “three-dimensional structure”). This technology calculates the cross-sectional shape sliced thinly in the stacking direction based on data (STL (Standard Triangulated Language) format data) that describes the surface of one three-dimensional structure as a collection of triangles. Is a technique for forming a three-dimensional structure by forming In addition, as a technique for modeling a three-dimensional structure, a melt deposition method (FDM: Fused Deposition Molding), an ink jet method, an ink jet binder method, an optical modeling method (SL: Stereo Lithography), a powder sintering method (SLS: Selective Molding) Laser Sintering) is known.

  As a three-dimensional modeling method using an inkjet method, for example, a step of selectively discharging, for example, a photocurable resin model material from an inkjet head to a modeling stage, a step of smoothing the surface, and curing the model material A technique for forming a three-dimensional structure by forming a single layer of a modeling material layer (cured layer) by a process (a light irradiation process in the case of a photocurable resin) and laminating a plurality of the modeling material layers is provided. Yes. According to such a method, a high-definition modeling material layer is formed by discharging the model material as minute droplets (droplet diameter: several tens [μm]) based on the three-dimensional shape of the modeling object. Therefore, a high-definition three-dimensional structure can be modeled by laminating them. In addition, by using an inkjet head having a length that does not require sub-scanning in which a plurality of discharge nozzles are arranged as an inkjet head (so-called line head), even a large three-dimensional structure can be produced in a relatively short time. It has been devised so that it can be shaped with.

  Moreover, in the said three-dimensional modeling method, the support material for supporting a model material is supplied with respect to a modeling stage during modeling of a three-dimensional molded item. The support material is provided on the outer periphery or inner periphery of the model material, for example, when the modeling target has an overhanging part (overhanging part), and the overhanging part until the modeling of the three-dimensional structure is completed. Support. The support material is removed after the modeling of the three-dimensional structure is completed.

  2. Description of the Related Art Generally, as a three-dimensional modeling apparatus using an ink jet method, one that discharges both a model material and a support material with a liquid is known (for example, see Patent Document 1). In such a three-dimensional modeling apparatus, both the model material and the support material can be precisely formed by an inkjet method, and a three-dimensional modeled object having excellent shape reproducibility is easily obtained.

  On the other hand, recently, it has been demanded that not only the overall shape reproducibility of a three-dimensional structure but also the surface state of the three-dimensional structure can be controlled. For example, in order to optimize the grip feeling of a product (three-dimensional structure), there may be a scene where a plurality of prototypes with different surface roughness are required. In such a scene, it is required that the surface roughness of the three-dimensional structure can be created according to the user's aim.

  For example, in Patent Document 1, the interface between the model material and the support material adjacent to each other on the same line is uncured by discharging and curing only one of the model material and the support material at the same time. Thus, a technique for avoiding the situation of mixing is disclosed.

JP2012-96429A

  However, until now, the actual situation is that a three-dimensional modeling apparatus capable of controlling the surface roughness as intended by the user has not been sufficiently studied. For example, in Patent Document 1 described above, the model material and the support material are not discharged at the same time, but only one of them is discharged and cured, so that the interface between the adjacent model material and the support material on the same line is uncured. Thus, a technique for avoiding the situation of mixing is disclosed. In Patent Document 1, if both are mixed at the interface portion between the adjacent model material and the support material to produce a mixed portion, it is assumed that the modeling quality deteriorates and the support material is difficult to remove. In order to prevent this, it is hardened after discharging one side so as not to produce a mixing part. Therefore, with the technique described in Patent Document 1, it is difficult to control the surface roughness of the finally obtained shaped article as intended by the user.

  An object of the present invention is to provide a three-dimensional modeling apparatus and a three-dimensional modeling method capable of modeling a three-dimensional structure having a surface roughness desired by a user.

The three-dimensional modeling apparatus according to the present invention is
A first modeling material region made of an energy curable first modeling material and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling material during modeling and is removed after the modeling is completed. A modeling stage on which a plurality of modeling material layers including a modeling material layer having
A first modeling material region forming unit that discharges the first modeling material to form the first modeling material region;
A second modeling material region forming unit that discharges the second modeling material to form the second modeling material region;
An energy applying device that applies energy to cure at least one of the first modeling material region and the second modeling material region;
A control unit that controls at least the energy application device;
With
The control unit is applied to the one area after the one area is formed and before the other area is formed between the first modeling material area and the second modeling material area. The first modeling material and the second at the interface between the first modeling material region and the second modeling material region, which are formed when the other region is formed by changing the amount of energy to be generated. Adjust the degree of mixing with the modeling material,
It is characterized by that.

The three-dimensional modeling apparatus according to the present invention is
A first modeling material region made of an energy curable first modeling material and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling material and is removed after the modeling is completed. A modeling stage on which a plurality of modeling material layers including a modeling material layer are stacked;
A first modeling material region forming unit that discharges the first modeling material to form the first modeling material region;
A second modeling material region forming unit that discharges the second modeling material to form the second modeling material region;
A first energy applying device that applies first energy for curing one of the first modeling material region and the second modeling material region to at least one region;
A second energy application device that applies second energy to the modeling material layer;
A control unit for controlling at least the first and second energy applying devices;
With
After the one region is formed, the control unit applies the first energy to the one region and semi-cures the first region so as to contact the semi-cured one region. By changing the second amount of energy applied to the interface between the first modeling material region and the second modeling material region after the other of the modeling material region and the second modeling material region is formed. Adjusting the degree of mixing of the first modeling material and the second modeling material at the interface part,
It is characterized by that.

The three-dimensional modeling method according to the present invention is:
Receive information about the surface condition of the 3D object to be modeled,
A first modeling material region made of an energy curable first modeling material, and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling region during modeling and is removed after the modeling is completed. Forming one region of
Applying an amount of energy adjusted based on the information to the one region to advance curing,
The first modeling material region is formed such that the other one of the first modeling material region and the second modeling material region is in contact with the one region to which energy is applied, and faces the second modeling material region. The interface portion of the material region is in a surface state corresponding to the information.

  According to the present invention, it is possible to adjust the degree of mixing of the first modeling material and the second modeling material at the interface between the first modeling material region and the second modeling material region. The degree of unevenness remaining at the interface can be adjusted. Therefore, the surface state on the surface of the final three-dimensional structure from which the second modeling material region is removed (that is, the interface between the first modeling material region and the second modeling material region) can be controlled. That is, a three-dimensional structure having a surface state desired by the user can be formed.

It is a figure which shows schematically the structure of the three-dimensional modeling apparatus which concerns on 1st Embodiment. It is a figure which shows the principal part of the control system of the three-dimensional modeling apparatus which concerns on 1st Embodiment. It is a figure which shows the structure of the head unit which concerns on 1st Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 1st Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 1st Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 1st Embodiment. It is a flowchart which shows the operation example which designates the surface roughness of the three-dimensional structure based on 1st Embodiment. It is a figure which shows schematically the structure of the three-dimensional modeling apparatus which concerns on 2nd Embodiment. It is a figure which shows the principal part of the control system of the three-dimensional modeling apparatus which concerns on 2nd Embodiment. It is a figure which shows the structure of the ultrasonic irradiation unit which concerns on 2nd Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 2nd Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 2nd Embodiment. It is a figure explaining the example of 3D modeling operation | movement of the 3D modeling apparatus which concerns on 2nd Embodiment. It is a flowchart which shows the operation example which designates the surface roughness of the three-dimensional structure based on 2nd Embodiment. It is a figure which shows the structure of the temperature adjustment part provided below the modeling stage. It is a figure which shows the modification of a structure of the head unit which concerns on 1st and 2nd embodiment. It is a figure explaining the three-dimensional modeling operation example of a three-dimensional modeling apparatus. It is a figure explaining the three-dimensional modeling operation example of a three-dimensional modeling apparatus. It is a table | surface showing the result of evaluation experiment.

<First Embodiment>
Hereinafter, a first embodiment will be described in detail with reference to the drawings. FIG. 1 is a diagram schematically showing a configuration of a three-dimensional modeling apparatus 100 according to the first embodiment. FIG. 2 is a diagram illustrating a main part of a control system of the three-dimensional modeling apparatus 100 according to the first embodiment. The three-dimensional modeling apparatus 100 shown in FIGS. 1 and 2 supports and / or supports the model material in contact with the model material during the modeling operation of the three-dimensional model 200 and the model material that is the first modeling material on the modeling stage 140. The three-dimensional structure 200 is formed by sequentially forming and stacking a plurality of modeling material layers including a modeling material layer made up of a support material that is a second modeling material for covering. The support material is provided on the outer periphery or inner periphery of the model material, for example, when the object to be modeled has an overhanging part (overhanging part), and overhangs until the modeling of the three-dimensional model 200 is completed. Support the part (model material). The support material is removed by the user after the modeling of the three-dimensional structure 200 is completed. As the model material and the support material, an energy curable material that is cured by applying energy such as light, heat, and radiation is used. Energy curable materials such as photo-curing resin materials and thermosetting resin materials have a relatively low viscosity, and it is possible to produce highly accurate shaped objects by discharging them from an inkjet-type discharge head described later. . In the present embodiment, description will be made assuming that a photocurable material is used as the model material and the support material.

  The three-dimensional modeling apparatus 100 includes a control unit 110 for performing control of each unit and handling of 3D data, a storage unit 115 for storing various types of information including a control program executed by the control unit 110 and surface roughness designation information, which will be described later. Head unit 120 for performing modeling using model material to be moved, moving mechanism 130 for moving head unit 120, modeling stage 140 on which a model is formed, display unit 145 for displaying various information, external device A data input unit 150 for transmitting and receiving various types of information such as 3D data, and an operation unit 160 for receiving instructions from the user. The 3D modeling apparatus 100 is a computer for designing a modeling object or for generating modeling data based on 3D information obtained by measuring an actual object using a 3D measuring machine. A device 155 is connected.

  The data input unit 150 receives 3D data (CAD data, design data, etc.) indicating the three-dimensional shape of the modeling object from the computer device 155 and outputs it to the control unit 110. The CAD data and the design data are not limited to the three-dimensional shape of the modeling object, but may include color image information on a part or the entire surface of the modeling object and inside. The method for acquiring 3D data is not particularly limited, and may be acquired using short-range wireless communication such as wired communication, wireless communication, Bluetooth (registered trademark), or a USB (Universal Serial Bus) memory. You may acquire using this recording medium. The 3D data may be acquired from a server that manages and stores the 3D data.

  The control unit 110 includes calculation means such as a CPU (Central Processing Unit), acquires 3D data from the data input unit 150, and performs analysis processing and calculation processing of the acquired 3D data. The control unit 110 analyzes the 3D data to set a region constituting the three-dimensional structure 200 as a model material region formed using a model material. Moreover, the control part 110 sets the area | region which supports the model material which comprises the three-dimensional structure 200 to the support material area | region formed using a support material.

  The control unit 110 converts the 3D data acquired from the data input unit 150 into a plurality of slice data sliced in the stacking direction. The slice data is data for each modeling material layer for modeling the three-dimensional structure 200. A model material area and a support material area are set for each slice data. The thickness of the slice data, that is, the thickness of the modeling material layer coincides with the distance (lamination pitch) corresponding to the thickness of one layer of the modeling material layer. For example, when the thickness of the modeling material layer is 0.05 [mm], the control unit 110 cuts out continuous 20 [sheets] slice data necessary for stacking with a height of 1 [mm] from the 3D data.

  Moreover, the control part 110 controls operation | movement of the three-dimensional modeling apparatus 100 whole during modeling operation | movement of the three-dimensional structure 200. FIG. For example, mechanism control information for discharging the model material and the support material to a desired location is output to the moving mechanism 130 and slice data is output to the head unit 120. That is, the control unit 110 controls the head unit 120 and the moving mechanism 130 in synchronization. The control unit 110 also controls the light source 126 described later.

  The display unit 145 displays various information and messages to be recognized by the user under the control of the control unit 110. The operation unit 160 includes various operation keys such as a numeric keypad, an execution key, and a start key, receives various input operations by the user, and outputs an operation signal to the control unit 110. The designation of the surface roughness of the three-dimensional structure 200, which will be described later, is performed by operating the operation unit 160.

  The modeling stage 140 is disposed below the head unit 120. A modeling material layer is formed on the modeling stage 140 by the head unit 120, and the modeling material layer is laminated, whereby the three-dimensional model 200 including the support material region is modeled.

  The moving mechanism 130 changes the relative position between the head unit 120 and the modeling stage 140 in three dimensions. Specifically, as shown in FIG. 1, the moving mechanism 130 includes a main scanning direction guide 132 that engages with the head unit 120, a sub scanning direction guide 134 that guides the main scanning direction guide 132 in the sub scanning direction, A vertical direction guide 136 that guides the modeling stage 140 in the vertical direction, and a drive mechanism including a motor, a drive reel, and the like not shown.

  The moving mechanism 130 drives a motor and a driving mechanism (not shown) according to the mechanism control information output from the control unit 110 and moves the head unit 120 freely in the main scanning direction and the sub-scanning direction (see FIG. 1). The moving mechanism 130 may be configured to fix the position of the head unit 120 and move the modeling stage 140 in the main scanning direction and the sub-scanning direction, or both the head unit 120 and the modeling stage 140 may be moved. You may comprise so that it may move.

  In addition, the moving mechanism 130 drives a motor and a driving mechanism (not shown) according to the mechanism control information output from the control unit 110, and moves the modeling stage 140 downward in the vertical direction so that the head unit 120, the three-dimensional model 200, (See FIG. 1). That is, the modeling stage 140 is configured to be movable in the vertical direction by the moving mechanism 130, and after the Nth modeling material layer is formed on the modeling stage 140, where N is a natural number, Move vertically downward by the pitch. Then, after the (N + 1) th modeling material layer is formed on the modeling stage 140, it moves again downward in the vertical direction by the stacking pitch. The moving mechanism 130 may fix the vertical position of the modeling stage 140 and move the head unit 120 upward in the vertical direction, or may move both the head unit 120 and the modeling stage 140.

  As shown in FIGS. 2 and 3, the head unit 120 includes an inkjet first discharge head 122 and a second discharge head 124, a smoothing device 125, and a light source 126 (functioning as a curing unit) inside the housing 121. . The first discharge head 122 constitutes a part of a model material region forming unit for forming the model material region in the modeling material layer, and the second discharge head 124 sets the support material region in the modeling material layer. A part of the support material region forming part for forming is formed.

  The first discharge head 122 has a plurality of discharge nozzles arranged in a row in the longitudinal direction (sub-scanning direction). The first discharge head 122 selectively discharges droplets of the model material from the plurality of discharge nozzles toward the modeling stage 140 while scanning in the main scanning direction orthogonal to the longitudinal direction. When the modeling material layer for one layer is formed, the first ejection head 122 ejects a droplet of the model material to an area where the model material area is set with respect to slice data corresponding to the modeling material layer. . By repeating this discharge operation a plurality of times while shifting in the sub-scanning direction, a model material region of the modeling material layer is formed in a desired region on the modeling stage 140. The model material region is cured by being subjected to a curing process by irradiation with light energy. The degree of curing depends on the amount of energy applied and can be in a semi-cured state or in a substantially completely cured state. Here, the semi-curing refers to a state in which the model material is cured at a degree lower than the complete curing so that the model material has a viscosity that can maintain the shape as a layer (modeling material layer).

  The second ejection head 124 has a plurality of ejection nozzles arranged in a row in the longitudinal direction (sub-scanning direction). The second ejection head 124 selectively ejects droplets of the support material from the plurality of ejection nozzles toward the modeling stage 140 while scanning in the main scanning direction orthogonal to the longitudinal direction. When the modeling material layer for one layer is formed, the second ejection head 124 ejects droplets of the support material to an area where the support material area is set for slice data corresponding to the modeling material layer. . By repeating this discharge operation a plurality of times while shifting in the sub-scanning direction, a support material region of the modeling material layer is formed in a desired region on the modeling stage 140.

  As described above, the moving mechanism 130 is operated by the control signal from the control unit 110 and the model material is selectively supplied from the first ejection head 122 to the modeling stage 140 based on the slice data sent from the control unit 110. Then, modeling is performed by the support material being selectively supplied from the second ejection head 124 to the modeling stage 140. That is, the control unit 110, the moving mechanism 130, the head unit 120, the first discharge head 122, and the like constitute a model material region forming unit for forming a model material region, and the control unit 110, the moving mechanism 130, the head unit 120, A support material region forming unit for forming a support material region is configured by the second ejection head 124 and the like.

  As the first ejection head 122 and the second ejection head 124, a conventionally known inkjet head for image formation is used. The plurality of discharge nozzles included in the first discharge head 122 and the second discharge head 124 may be arranged in a line, may be arranged in a straight line, or may be linear as a whole in a zigzag arrangement. You may line up like this.

  The first discharge head 122 stores the model material in a dischargeable state. In the present embodiment, as the first ejection head 122, for example, a head that can eject a model material in a range of 5 to 15 [mPa · s] can be employed. As the model material, a photocurable material that cures when irradiated with light (light energy) having a specific wavelength is used. Examples of the photocurable material include an ultraviolet curable resin, a radical polymerization type ultraviolet curable resin such as acrylic ester or vinyl ether, a monomer or oligomer such as epoxy or oxetane, and a polymerization initiator corresponding to the resin. As the (reaction initiator), a cationic polymerization ultraviolet curable resin that is used in combination with acetophenone, benzophenone, or the like can be used. The photocurable material can be stored in a dischargeable state by blocking light of a specific wavelength that can be cured by a light shielding member or a filter. As the model material, a thermosetting material that is cured by application of thermal energy may be used, or a radiation curable material that is cured by irradiation with radiation may be used.

  The second discharge head 124 stores the support material in a dischargeable state. As the support material, a photo-curing material that is cured when irradiated with light of a specific wavelength is used by changing the blending ratio with the model material. By adding polyethylene glycol, partially acrylated polyhydric alcohols / oligomers, acrylated oligomers with hydrophilic substituents, or combinations of these materials to the support material, it swells against contact with water. It may have a function. As a result, the support material can be easily removed. As the support material, a thermosetting material that is cured by applying thermal energy may be used, or a radiation curable material that is cured by irradiation of radiation may be used, and these materials have water swellability. You may use the made material.

  The model material and the support material are respectively discharged onto the modeling stage 140 by the first discharge head 122 and the second discharge head 124 to form a modeling material layer (model material region and support material region). The modeling material layer is cured until it is hard enough to obtain a sufficient strength by being subjected to a curing process by irradiation with light energy.

  The smoothing device 125 includes a leveling roller 125 </ b> A, a scraping member 125 </ b> B (blade), and a recovery member 125 </ b> C inside the housing 121. The leveling roller 125 </ b> A can be rotationally driven under the control of the control unit 110, and comes into contact with the model material surface and the support material surface discharged by the first discharge head 122 and the second discharge head 124, so as to contact the model material surface and the support. Smooth the irregularities on the surface of the material. As a result, a modeling material layer (a model material region and a support material region) having a uniform layer thickness is formed. Since the surface of the modeling material layer is smoothed, the next modeling material layer can be accurately formed and stacked, so that the highly accurate three-dimensional model 200 can be modeled. The model material and the support material adhering to the surface of the leveling roller 125A are scraped off by a scraping member 125B provided in the vicinity of the leveling roller 125A. The model material and the support material scraped by the scraping member 125B are collected by the collecting member 125C. The model material and the support material scraped by the scraping member 125B may be supplied to the first discharge head 122 or the second discharge head 124 and reused, or a waste tank (not shown). It is good also as what is transported to.

  The light source 126 as an energy applying device performs a curing process (light energy irradiation process) on the model material and the support material of the photocurable resin discharged toward the modeling stage 140 and semi-cures them. When an ultraviolet curable material is used as the model material, a UV lamp (for example, a high-pressure mercury lamp) that emits ultraviolet light is preferably used as the light source 126. In addition to the high pressure mercury lamp, a low pressure mercury lamp, a medium pressure mercury lamp, an ultra high pressure mercury lamp, a carbon arc lamp, a metal halide lamp, a xenon lamp, an ultraviolet LED lamp, or the like can be used as the light source 126. In the light source 126, the irradiation timing and the exposure amount are controlled by a control signal from the control unit 110. The exposure amount may be controlled by adjusting the voltage or current applied to the light source 126 to change the light emission intensity of the light source 126, or an optical filter between the light source 126 and the modeling material. It is also possible to arrange so as to be able to be inserted and removed, or to be configured so that a plurality of types of filters can be switched, and these may be inserted and removed or switched.

  Next, with reference to FIGS. 4 to 6 schematically shown, an operation example in which the three-dimensional modeling apparatus 100 forms the three-dimensional model 200 by sequentially forming and stacking the modeling material layers will be described. As shown in FIG. 4A, the three-dimensional modeling apparatus 100 includes four modeling material layers by sequentially forming and stacking modeling material layers having a model material region and a support material region on the modeling stage 140. A case where a three-dimensional structure 200 (broken line portion in the figure, the same applies hereinafter) is formed will be described. In the present embodiment, in advance, the user designates the surface state (surface roughness in this case) of the side surface of the three-dimensional structure 200 finally obtained by operating the numeric keypad and execution key of the operation unit 160 or the like. The surface roughness designation information is input and stored in the storage unit 115 functioning as an information receiving unit. The surface roughness designation information may be included in the 3D data sent from the external computer device 155, and this information may be extracted by the control unit 110 and stored in the storage unit 115.

  First, as shown in FIG. 4B, the head unit 120 discharges the support material 220 </ b> A while scanning from one end on the modeling stage 140 to the other end in the main scanning direction, and toward the modeling stage 140. The support material 220A discharged in this manner is subjected to a curing process (light energy irradiation process) to advance the curing to a predetermined degree (first operation). Next, the head unit 120 temporarily stops the ejection of the support material 220A, and scans from the other end on the modeling stage 140 to one end in the main scanning direction (second operation). Next, the head unit 120 scans in the sub-scanning direction so that the ejection positions of the support material 220A by the head unit 120 do not overlap (third operation). During the second operation and the third operation, the modeling stage 140 may be temporarily moved downward in the moving mechanism 130 in the vertical direction. By repeating these first to third operations, a predetermined region on the modeling stage 140 is scanned to form the first modeling material layer (support material region 220). In the present embodiment, the control unit 110 changes the amount of light energy applied to the support material region 220 according to the surface roughness of the three-dimensional structure 200 specified by the operation of the operation unit 160 or the like. The cured state of the support material region 220 is controlled. For example, the amount of light energy applied to the support material region 220 is changed by changing the time for irradiating a predetermined amount of light energy or changing the intensity of the applied light energy. Here, when it is desired to roughen the surface state of the three-dimensional structure 200 to be finally obtained, the amount of light energy applied to the support material region 220 is reduced, and when it is desired to be smooth, the amount of light energy is relatively Enlarge. In order to change the amount of energy, both the intensity of energy and the irradiation time may be changed. In the third operation, for example, when the resolution is increased by moving the head unit 120 in the sub-scanning direction by a distance equal to or less than the pitch of the discharge nozzles, the cured state of the support material region 220 is changed. In order to make it as uniform as possible, the exposure by the light source 126 may not be performed during the first operation, and the first to third operations may be repeated as many times as necessary, and then the exposure may be performed collectively.

  Next, as shown in FIG. 4C, the head unit 120 discharges the model material 210A while scanning from one end on the modeling stage 140 to the other end in the main scanning direction (fourth operation). Next, the head unit 120 temporarily stops the ejection of the model material 210A and scans from the other end on the modeling stage 140 to one end in the main scanning direction (fifth operation). Next, the head unit 120 scans in the sub-scanning direction so that the ejection positions of the model material 210A by the head unit 120 do not overlap (sixth operation). During the fifth operation and the sixth operation, the modeling stage 140 may be temporarily lowered in the vertical direction by the moving mechanism 130. By repeating these fourth to sixth operations, a predetermined region on the modeling stage 140 is scanned to form the first modeling material layer (model material region 210). In the present embodiment, when the model material region 210 is formed according to the cured state of the support material region 220, the model material 210A and the support material 220A at the interface 230 between the model material region 210 and the support material region 220 The degree of mixing changes. According to the inventor's study, after one of the model material and the support material is in a semi-cured state, when the other is brought into contact with each other, the two are mixed at the interface, and the degree of this mixing is that of the one modeling material. It has been found that it changes depending on the degree of curing, and that the surface state of the finally obtained three-dimensional structure 200 can be changed using this change. That is, the interface part 230 of the model material region 210 facing the support material region 220 is stored in the storage unit 115 by forming the model material region 210 to which energy is applied in contact with the support material region 220. A surface state corresponding to information on the surface state (here, surface roughness designation information) can be obtained. Here, when the degree of cure of the support material region 220 is small, the degree of mixing of both increases, and as a result, the degree of unevenness remaining at the interface 230 after the completion of curing increases. Further, when the degree of curing of the support material region 220 is large, the degree of mixing of both is low, and as a result, the degree of unevenness remaining at the interface 230 after the completion of curing is small. In FIG. 4C, for easy understanding, a state in which the roughness of the interface portion is increased by mixing the modeling materials is exaggerated. The same applies to FIGS. 5 and 6 described below.

  Next, as shown in FIG. 5A, the head unit 120 scans the model material region 210 and the support material region 220 that have been formed while scanning from one end to the other end on the modeling stage 140 in the main scanning direction. Is cured by being cured (seventh operation). Next, the head unit 120 temporarily stops the curing process, and scans from the other end on the modeling stage 140 to one end in the main scanning direction (eighth operation). Next, the head unit 120 scans in the sub-scanning direction so that the light irradiation positions by the head unit 120 do not overlap (the ninth operation). By repeating these seventh to ninth operations, the entire first modeling material layer (the model material region 210 and the support material region 220) is cured.

  Next, as shown in FIG. 5B, the head unit 120 scans a predetermined region on the modeling stage 140 by repeating the first to third operations described above, and the second modeling material layer (support The material region 220) is formed, and the support material region 220 is subjected to a curing process to advance the curing to a predetermined hardness.

  Next, as illustrated in FIG. 5C, the head unit 120 scans a predetermined region on the modeling stage 140 by repeating the above-described fourth to sixth operations, and a second modeling material layer (model) Material region 210) is formed.

  Next, as shown in FIG. 6A, the head unit 120 hardens the entire second modeling material layer (the model material region 210 and the support material region 220) by repeating the seventh to ninth operations described above. Let

  Thereafter, as shown in FIG. 6B, the head unit 120 repeats the first operation to the ninth operation described above to sequentially form the third and fourth modeling material layers (the model material region 210 and the support material region 220). Then, the entire third and fourth modeling material layers are sequentially cured. Thus, the modeling of the three-dimensional structure 200 is completed.

  As shown in FIG. 6C, the support material region 220 is removed by the user from the three-dimensional structure 200 including the obtained support material. Thereby, the three-dimensional structure 200 not including the support material is obtained. In the present embodiment, the degree of unevenness remaining at the interface 230 between the model material region 210 and the support material region 220 is adjusted to match the surface roughness specified by the user.

  FIG. 7 is a control flowchart for designating the surface roughness of the three-dimensional structure 200 in the three-dimensional structure forming apparatus 100, which is executed by the control unit 110. The process of step S100 starts when a surface roughness designation mode for designating the surface roughness of the three-dimensional structure 200 is selected by a user operation via the operation unit 160.

  First, the control unit 110 starts processing based on surface roughness designation information designated by a user operation via the operation unit 160 or surface roughness designation information included in 3D data received by the data input unit 150. First, in step S100, whether or not the input surface roughness information is designated to a value (that is, a coarser value) larger than a default value (for example, 5 [μm]) stored in the storage unit 115. (Step S100). As a result of this determination, when a value larger than the default value (for example, 7 [μm]) is specified (step S100, YES), the control unit 110 forms the model material region when forming one modeling material layer. Setting is made to reduce the amount of light energy (curing energy amount) irradiated to the support material region 220 formed before 210 (step S120). With this setting, when the model material region 210 is formed, the degree of mixing of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 (the degree of unevenness remaining in the interface 230 after curing) Is adjusted to be large. As a result, the surface roughness of the final surface of the three-dimensional structure 200 (the interface portion 230 between the model material region 210 and the support material region 220) can be roughened. When the process of step S120 is completed, the three-dimensional modeling apparatus 100 ends the process in FIG.

  On the other hand, when a value larger than the default value is not specified (step S100, NO), the control unit 110 has a value smaller than the default value (for example, 3 [μm]) as the surface roughness of the three-dimensional structure 200. It is determined whether or not a finer value has been designated (step S140). As a result of this determination, when a value smaller than the default value is specified (step S140, YES), the control unit 110 supports the support formed before the model material region 210 when forming one modeling material layer. Settings are made to increase the amount of light energy applied to the material region 220 (step S160). With this setting, when the model material region 210 is formed, the mixing degree of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 is adjusted to be small. As a result, the surface roughness of the final surface of the three-dimensional structure 200 (the interface portion 230 between the model material region 210 and the support material region 220) can be reduced. When the process of step S160 is completed, the three-dimensional modeling apparatus 100 ends the process in FIG.

  On the other hand, if a value smaller than the default value is not designated (step S140, NO), the 3D modeling apparatus 100 ends the process in FIG. In this case, when forming the modeling material layer for one layer, the control unit 110 does not change the light energy amount applied to the support material region 220 formed before the model material region 210 from the default light energy amount. As described above, in the surface roughness designation mode for designating the surface roughness of the three-dimensional structure 200, the user arbitrarily designates the desired surface roughness (rougher, default or finer), and the surface The three-dimensional structure 200 having roughness can be formed by the three-dimensional structure forming apparatus 100.

[Effect in the first embodiment]
As described above in detail, in the first embodiment, the three-dimensional modeling apparatus 100 is in contact with the model material area 210 made of an energy curable model material and the model material during modeling and is removed after the modeling is completed. A modeling stage 140 on which a plurality of modeling material layers including a modeling material layer having a support material region 220 made of an energy curable support material is laminated, and a model material is discharged to form a model material region 210. With respect to at least one of the first modeling material region forming unit, the second modeling material region forming unit that discharges the support material to form the supporting material region 220, and the model material region 210 and the supporting material region 220, The light source 126 which provides the energy for hardening one area | region and the control part 110 which controls the light source 126 at least are provided. The controller 110 changes the amount of energy applied to one region after the one region is formed and before the other region of the model material region 210 and the support material region 220 is formed. Thus, the mixing degree of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 formed when the other region is formed is adjusted.

  According to the first embodiment configured as described above, the degree of mixing of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 can be adjusted. The degree of unevenness remaining on the interface 230 later can be adjusted. Therefore, the surface roughness on the surface of the final three-dimensional structure from which the support material region 220 has been removed (the interface portion 230 between the model material region 210 and the support material region 220) can be made differently. That is, the three-dimensional structure 200 having the surface roughness desired by the user can be formed.

  In the first embodiment, the example in which the model material region 210 is formed after the support material region 220 is formed when the modeling material layer for one layer is formed has been described. However, the model material region 210 is formed. After that, the support material region 220 may be formed.

<Second Embodiment>
Hereinafter, a second embodiment will be described in detail with reference to the drawings. FIG. 8 is a diagram schematically showing the configuration of the three-dimensional modeling apparatus 100 according to the second embodiment. FIG. 9 is a diagram illustrating a main part of a control system of the three-dimensional modeling apparatus 100 according to the second embodiment. As shown in FIGS. 8 and 9, the three-dimensional modeling apparatus 100 includes an ultrasonic irradiation unit as an ultrasonic irradiation unit for irradiating ultrasonic waves toward the modeling material layer in addition to the configurations shown in FIGS. 128 is further provided. That is, the 3D modeling apparatus 100 includes a light source 126 as a first energy applying device for applying energy to at least one of the model material region and the support material region, and the model material region and the support material region. And a second energy applying device for applying energy to the other. In addition, the same code | symbol is attached | subjected about the thing similar to each part structure in 1st Embodiment, and the description is abbreviate | omitted.

  The controller 110 controls the entire operation of the three-dimensional modeling apparatus 100 during the modeling operation of the three-dimensional structure 200. For example, mechanism control information for discharging the model material and the support material to a desired place is output to the moving mechanism 130 and slice data is output to the head unit 120 and the ultrasonic irradiation unit 128. That is, the control unit 110 controls the head unit 120, the ultrasonic irradiation unit 128, and the moving mechanism 130 in synchronization.

  The moving mechanism 130 changes the relative positions of the head unit 120 and the ultrasonic irradiation unit 128 and the modeling stage 140 in three dimensions. Specifically, as shown in FIG. 8, the moving mechanism 130 includes a main scanning direction guide 132 that engages with the head unit 120 and the ultrasonic irradiation unit 128 and a sub scanning direction guide 132 that guides the main scanning direction guide 132 in the sub scanning direction. A scanning direction guide 134 and a vertical direction guide 136 for guiding the modeling stage 140 in the vertical direction are provided, and further, a driving mechanism including a motor, a driving reel, and the like (not shown) is provided.

  The moving mechanism 130 drives a motor and a driving mechanism (not shown) according to the mechanism control information output from the control unit 110, and freely moves the head unit 120 and the ultrasonic irradiation unit 128 in the main scanning direction and the sub-scanning direction ( (See FIG. 8). The moving mechanism 130 may be configured to fix the positions of the head unit 120 and the ultrasonic irradiation unit 128 and move the modeling stage 140 in the main scanning direction and the sub-scanning direction. You may comprise so that both the sound wave irradiation unit 128 and the modeling stage 140 may be moved. Further, the moving mechanism 130 may include two main scanning direction guides 132 so that each of the head unit 120 and the ultrasonic irradiation unit 128 is engaged with each of the two main scanning direction guides 132. .

  In the present embodiment, in order to freely move the head unit 120 in the main scanning direction, the ultrasonic irradiation unit 128 is moved as necessary so as not to hinder the movement of the head unit 120. Further, in order to freely move the ultrasonic irradiation unit 128 in the main scanning direction, the head unit 120 is moved as necessary so as not to hinder the movement of the ultrasonic irradiation unit 128. With respect to the head unit 120 and the ultrasonic irradiation unit 128, retract positions that do not interfere with each other may be set and moved to the respective retract positions.

  In addition, the moving mechanism 130 drives a motor and a driving mechanism (not shown) according to the mechanism control information output from the control unit 110, and moves the modeling stage 140 downward in the vertical direction so that the head unit 120 and the ultrasonic irradiation unit 128 The interval with the three-dimensional structure 200 is adjusted (see FIG. 8). That is, the modeling stage 140 is configured to be movable in the vertical direction by the moving mechanism 130, and after the Nth modeling material layer is formed on the modeling stage 140, the modeling stage 140 moves downward in the vertical direction by the stacking pitch. Then, after the (N + 1) th modeling material layer is formed on the modeling stage 140, it moves again downward in the vertical direction by the stacking pitch. The moving mechanism 130 may fix the vertical position of the modeling stage 140 and move the head unit 120 and the ultrasonic irradiation unit 128 upward in the vertical direction, or the head unit 120 and the ultrasonic irradiation unit 128 may be combined with the modeling. Both the stage 140 and the stage 140 may be moved.

  As shown in FIG. 10, the ultrasonic irradiation unit 128 includes an ultrasonic irradiation device 170 that selectively irradiates ultrasonic waves toward the modeling stage 140 inside the housing 129. The ultrasonic generator 170 may irradiate ultrasonic waves in a circular predetermined range, or may be a plurality of these arranged in a line. In the former case, the moving mechanism 130 may scan as many times as necessary so that ultrasonic waves act on the entire modeling material layer. The latter is effective in reducing the number of scans. Under the control of the control unit 110, the ultrasonic irradiation device 170 switches between ultrasonic irradiation and stop, and changes the intensity of the ultrasonic wave to be irradiated, the irradiation time of the ultrasonic wave, and the like. In the present embodiment, the ultrasonic irradiation apparatus 170 irradiates the interface 230 between the model material region 210 and the support material region 220 with ultrasonic waves when one modeling material layer is formed.

  Next, with reference to FIGS. 11-13, the operation example which models the three-dimensional structure 200 by the three-dimensional modeling apparatus 100 forming a modeling material layer in order and laminating | stacking is demonstrated. As shown in FIG. 11A, the three-dimensional modeling apparatus 100 includes four modeling material layers by sequentially forming and stacking a modeling material layer having a model material region and a support material region on the modeling stage 140. A case where a three-dimensional structure 200 (broken line portion in the figure, the same applies hereinafter) is formed will be described.

  First, as shown in FIG. 11B, the head unit 120 discharges the model material 210 </ b> A while scanning from one end on the modeling stage 140 to the other end in the main scanning direction, and toward the modeling stage 140. The model material 210A discharged in this manner is subjected to a curing process (light energy irradiation process) to be semi-cured (first operation). Next, the head unit 120 temporarily stops the ejection of the model material 210A, and scans from the other end on the modeling stage 140 to one end in the main scanning direction (second operation). Next, the head unit 120 scans in the sub-scanning direction so that the ejection positions of the model material 210A by the head unit 120 do not overlap (third operation). By repeating these first to third operations, a predetermined region on the modeling stage 140 is scanned to form a first modeling material layer (model material region 210). In the present embodiment, the control unit 110 changes the amount of light energy applied to the model material region 210 in accordance with the surface roughness designation information input by operating the operation unit 160 or the like, so that the model material region 210 is changed. Control the curing state of For example, the amount of light energy applied to the model material region 210 is changed by changing the time for applying a predetermined amount of light energy.

  Next, as shown in FIG. 11C, the head unit 120 and the ultrasonic irradiation unit 128 eject the support material 220A while scanning from one end to the other end on the modeling stage 140 in the main scanning direction. Then, the support material region 220 is formed, and the interface portion 230 between the model material region 210 and the support material region 220 is irradiated with ultrasonic waves (fourth operation). Thereby, compared with the case where an ultrasonic wave is not irradiated to the interface part 230, the diffusion and mixing of the model material 210A and the support material 220A in the interface part 230 are promoted. The controller 110 adjusts the degree of mixing of the model material 210A and the support material 220A at the interface 230 by changing the intensity of the ultrasonic wave to be irradiated or the irradiation time of the ultrasonic wave. The diffusion and mixing of the model material 210A and the support material 220A at the interface 230 can be promoted as the intensity of the ultrasonic wave to be applied is increased and as the irradiation time of the ultrasonic wave is increased. . Next, the head unit 120 and the ultrasonic irradiation unit 128 temporarily stop the ejection of the support material 220A and the ultrasonic irradiation, and scan from the other end on the modeling stage 140 to one end in the main scanning direction. (Fifth operation). Next, the head unit 120 scans in the sub-scanning direction so that the ejection positions of the support material 220A by the head unit 120 do not overlap (sixth operation). By repeating these fourth to sixth operations, a predetermined region on the modeling stage 140 is scanned to form the first modeling material layer (support material region 220). In the present embodiment, the mixing of the model material 210A and the support material 220A at the interface 230 is performed by the curing process on the model material region 210 and the ultrasonic irradiation process on the interface 230 between the model material region 210 and the support material region 220. The degree, and thus the degree of unevenness remaining at the interface 230 after curing, is adjusted in a wider range.

  Next, as shown in FIG. 12A, the head unit 120 scans the model material region 210 and the support material region 220 that have been formed while scanning from one end to the other end on the modeling stage 140 in the main scanning direction. Is cured by being cured (seventh operation). Next, the head unit 120 temporarily stops the curing process, and scans from the other end on the modeling stage 140 to one end in the main scanning direction (eighth operation). Next, the head unit 120 scans in the sub-scanning direction so that the light irradiation positions by the head unit 120 do not overlap (the ninth operation). By repeating these seventh to ninth operations, the entire first modeling material layer (the model material region 210 and the support material region 220) is cured.

  Next, as illustrated in FIG. 12B, the head unit 120 scans a predetermined region on the modeling stage 140 by repeating the first to third operations described above, and the second modeling material layer (model) The material region 210) is formed, and the model material region 210 is subjected to a curing process to be semi-cured.

  Next, as illustrated in FIG. 12C, the head unit 120 and the ultrasonic irradiation unit 128 scan the predetermined region on the modeling stage 140 by repeating the above-described fourth to sixth operations, and the second layer The modeling material layer (support material region 220) is formed, and the interface portion 230 between the model material region 210 and the support material region 220 is irradiated with ultrasonic waves.

  Next, as shown in FIG. 13A, the head unit 120 hardens the entire second modeling material layer (the model material region 210 and the support material region 220) by repeating the seventh to ninth operations described above. Let

  Thereafter, as shown in FIG. 13B, the head unit 120 and the ultrasonic irradiation unit 128 repeat the first to ninth operations described above to thereby form the third and fourth modeling material layers (the model material region 210 and the support). The material regions 220) are sequentially formed, and the entire third and fourth modeling material layers are sequentially cured. When the third and fourth modeling material layers (the model material region 210 and the support material region 220) are formed, the model material region 210 is cured to advance to a predetermined hardness, and the model material region 210 is also cured. The ultrasonic wave is applied to the interface 230 between the support material region 220 and the support material region 220. Thus, the modeling of the three-dimensional structure 200 is completed.

  As shown in FIG. 13C, the support material region 220 is removed by the user from the obtained three-dimensional structure 200 including the support material. Thereby, the three-dimensional structure 200 not including the support material is obtained. In the present embodiment, the degree of unevenness remaining at the interface 230 between the model material region 210 and the support material region 220 is adjusted to match the surface roughness specified by the user.

  FIG. 14 is a control flowchart for designating the surface roughness of the three-dimensional structure 200 executed by the control unit 110. The processing in step S200 starts when a surface roughness designation mode for designating the surface roughness of the three-dimensional structure 200 is selected by a user operation via the operation unit 160.

  First, the control unit 110 starts processing based on surface roughness designation information designated by a user operation via the operation unit 160 or surface roughness designation information included in 3D data received by the data input unit 150. First, in step S200, whether or not the input surface roughness information is specified to be a value (that is, a coarser value) greater than a default value (for example, 5 [μm]) stored in the storage unit 115. (Step S200). As a result of this determination, when a value larger than the default value (for example, 7 [μm]) is designated (step S200, YES), the control unit 110 supports the support material region when forming one modeling material layer. Setting is made to decrease the amount of light energy (curing energy amount) irradiated to the model material region 210 formed before 220 (step S220). With this setting, when the support material region 220 is formed, the degree of mixing of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 (the degree of unevenness remaining in the interface 230 after curing) Is adjusted to be large. As a result, the surface roughness of the final surface of the three-dimensional structure 200 (the interface portion 230 between the model material region 210 and the support material region 220) can be roughened.

  Next, the control unit 110 determines whether or not a larger value (for example, 9 [μm], that is, a rougher value) is designated as the surface roughness of the three-dimensional structure 200 (step S240). If a larger value is specified as a result of this determination (step S240, YES), the control unit 110, when forming a modeling material layer for one layer, the interface between the model material region 210 and the support material region 220 230 is set to irradiate with ultrasonic waves (step S260). By this setting, the diffusion and mixing of the model material and the support material in the interface portion 230 is promoted compared to the case where the interface portion 230 is not irradiated with ultrasonic waves. As a result, the surface roughness on the surface of the final three-dimensional structure 200 can be made much rougher. When the process of step S260 is completed, the three-dimensional modeling apparatus 100 ends the process in FIG. On the other hand, when a larger value is not designated (step S240, NO), the 3D modeling apparatus 100 ends the process in FIG.

  Returning to the determination in step S200, when a value larger than the default value is not specified (step S200, NO), the control unit 110 has a value smaller than the default value (that is, finer) as the surface roughness of the three-dimensional structure 200. It is determined whether or not (value) is designated (step S280). When a value smaller than the default value is specified as a result of this determination (step S280, YES), the controller 110 forms a model formed before the support material region 220 when forming one modeling material layer. Settings are made to increase the amount of light energy applied to the material region 210 (step S300). With this setting, when the support material region 220 is formed, the mixing degree of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 is adjusted to be small. As a result, the surface roughness of the final surface of the three-dimensional structure 200 (the interface portion 230 between the model material region 210 and the support material region 220) can be reduced. When the process of step S300 is completed, the three-dimensional modeling apparatus 100 ends the process in FIG.

  On the other hand, when a value smaller than the default value is not designated (step S280, NO), the 3D modeling apparatus 100 ends the process in FIG. In this case, when forming the modeling material layer for one layer, the control unit 110 does not change the light energy amount irradiated to the model material region 210 formed before the support material region 220 from the default light energy amount. As described above, in the surface roughness designation mode for designating the surface roughness of the three-dimensional structure 200, the user can arbitrarily designate the desired surface roughness (much coarser, coarser, default or finer). The three-dimensional structure 200 having the surface roughness can be formed by the three-dimensional structure forming apparatus 100.

[Effects of Second Embodiment]
As described above in detail, in the second embodiment, when the three-dimensional modeling apparatus 100 forms one modeling material layer, the three-dimensional modeling apparatus 100 applies light to the model material region 210 formed before the support material region 220. In addition to irradiating energy, an ultrasonic wave is irradiated to the interface 230 between the model material region 210 and the support material region 220. Thereby, compared with the case where an ultrasonic wave is not irradiated to the interface part 230, the diffusion and mixing of the model material and the support material in the interface part 230 are promoted. As a result, the surface roughness of the surface of the final three-dimensional structure 200 can be made rougher than when no ultrasonic wave is irradiated. Therefore, the surface roughness of the three-dimensional structure 200 can be controlled in a wider range by using ultrasonic waves in combination with light irradiation. In addition, by changing at least one of the intensity of the ultrasonic wave and the irradiation time of the ultrasonic wave, the degree of mixing of the model material and the support material at the interface 230 can be finely adjusted. The surface roughness on the surface of the object 200 can be finely adjusted. In addition, the amount of energy applied to the modeling material in the first stage is fixed at a value such that the modeling material is semi-cured, and the amount of ultrasonic irradiation as energy applied to the modeling material in the second stage is changed. The mixing degree of the interface 230 may be adjusted.

<Other embodiments>
In the second embodiment, the example in which the head unit 120 and the ultrasonic irradiation unit 128 are separated has been described. However, the head unit 120 and the ultrasonic irradiation unit 128 may be integrated. it can.

  In the second embodiment, the example in which the support material region 220 is formed after the model material region 210 is formed when one modeling material layer is formed has been described. However, the support material region 220 is formed. After that, the model material region 210 may be formed.

  In the first and second embodiments, the degree of mixing of the model material and the support material at the interface 230 may be adjusted by changing the temperature around the modeling stage 140. FIG. 15 shows a configuration in which the temperature around the modeling stage 140 is adjusted using a known Peltier element that is a thermoelectric conversion element. As shown in FIG. 15, a Peltier element 180 is disposed below the modeling stage 140. The Peltier element 180 is energized by the power source 185 under the control of the control unit 110, whereby the modeling material layer (model material region 210 and support material region 220) formed around the modeling stage 140 and thus on the modeling stage 140. Adjust the temperature. That is, the Peltier element 180 and the power source 185 function as a temperature control unit for controlling the temperature around the modeling stage 140. For example, by keeping the temperature around the modeling stage 140 high, the viscosity of the model material and the support material discharged onto the modeling stage 140 decreases, and the model material at the interface 230 between the model material region 210 and the support material region 220 is reduced. In addition, diffusion and mixing of the support material is promoted. As a result, the surface roughness on the surface of the final three-dimensional structure 200 can be increased. On the other hand, by keeping the temperature around the modeling stage 140 low, the viscosity of the model material and the support material discharged onto the modeling stage 140 increases, and the model material at the interface 230 between the model material region 210 and the support material region 220 is increased. In addition, diffusion and mixing of the support material are suppressed. As a result, the surface roughness on the surface of the final three-dimensional structure 200 can be reduced. As described above, in addition to light irradiation, or in addition to light irradiation and ultrasonic irradiation, the adjustment range of the surface roughness of the three-dimensional structure 200 can be easily expanded by adjusting the temperature. Note that the surface roughness of the three-dimensional structure 200 may be adjusted by controlling the temperature around the modeling stage 140 while fixing by light irradiation to a certain degree.

  In the first and second embodiments, when forming a modeling material layer for one layer, the first curing process (curing process for the previously formed model material region 210 or support material region 220). Although an example in which the same light source 126 is used for the second curing process (the curing process for the entire modeling material layer) has been described, the present invention is not limited to this. Different light sources may be used for the first curing process and the second curing process. For example, when an ultraviolet curable material is used as the model material and the support material, as shown in FIG. 16, the light source 126 having a narrow ultraviolet wavelength distribution is used for the first curing process, and the ultraviolet wavelength distribution is wide for the second curing process. A light source 127 may be used. For example, ultraviolet LED lamps are preferably used as the light sources 126 and 127 having different ultraviolet wavelength distributions.

  In the first and second embodiments, a polymerization initiator is added to each of the model material and the support material so that the progress of curing in the model material and the support material can be changed with respect to the same wavelength light. You may mix appropriately. Further, the time from when the model material region 210 and the support material region 220 are formed to when the second curing process is started may be changed. Further, the wavelength of light used in the first curing process and the second curing process may be changed. Thereby, the mixing degree of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 can be adjusted, and the surface roughness on the surface of the final three-dimensional structure 200 is controlled. can do.

  In the first and second embodiments, the head unit 120 adjusts the viscosity of one of the model material region 210 and the support material region 220 that is formed first together with the model material and the support material. You may have the structure which discharges an agent. For example, the head unit 120 may be provided with a discharge head for a surface control agent different from the first discharge head 122 and the second discharge head 124, and the surface control agent may be discharged from the discharge head. The surface control agent may be discharged from another discharge head. By discharging the surface control agent, the mixing degree of the model material and the support material at the interface 230 between the model material region 210 and the support material region 220 can be adjusted, and the surface of the final three-dimensional structure 200 can be adjusted. The surface roughness at can be controlled. Examples of the surface control agent include a fluorine-based surfactant and a silicone-based surfactant (for example, BYK307 manufactured by BYK-Chemie).

  Moreover, you may make it vary a surface state according to the site | part of the three-dimensional structure 200. FIG. For example, by changing the energy amount of the light irradiated in the first stage according to the position in the stacking direction, a plurality of portions having different surface roughnesses can be formed in the stacking direction.

  Further, the target of the surface state control is not limited to the side surface of the three-dimensional structure 200 but may be the upper surface of the three-dimensional structure 200 or the lower surface of the overhang portion. For example, in the process of FIG. 5A of the first embodiment, the amount of light irradiated to the model material region 210 is adjusted to control the curing state of the model material (FIG. 17A), and then the model material is used as the second layer. When the support material region 220 is formed on the region 210, mixing occurs between the upper surface of the model material region 210 and the support material region 220. Here, as shown in FIG. 17B, the upper surface of the model material region 210 is also controlled in the surface state by forming the support material region 220 so as to cover the part that finally becomes the upper surface of the three-dimensional structure 200. can do. After that, by repeating the formation of the model material and the formation of the support material as shown in FIG. 17C and FIG. The state can be controlled.

  In addition, the first and second embodiments are merely examples of implementation in carrying out the present invention, and the technical scope of the present invention is interpreted in a limited manner. It must not be. That is, the present invention can be implemented in various forms without departing from the gist or the main features thereof.

[Experimental example]
An evaluation experiment for confirming the effects in the configurations of the first and second embodiments will be described. FIG. 19 is a table showing the results of an evaluation experiment performed using an experimental apparatus having the configuration shown in FIGS. In this evaluation experiment, as a model material, 15 parts by mass of urethane acrylate monomer, 20 parts by mass of acryloylmorpholine, 15 parts by mass of tricyclodecane dimethanol diacrylate, 30 parts by mass of isobornyl acrylate, Irgacure 184 (polymerization initiator) 3 An ultraviolet curable resin material comprising, by weight, 2 parts by weight of lucillin TPO (polymerization initiator), 10 parts by weight of 2-hydroxy-3-phenoxypropyl acrylate, 3 parts by weight of bisphenol A epoxy diacrylate, and 2 parts by weight of byk307. Using. Further, as a support material, 3 parts by mass of Irgacure 184 (polymerization initiator), 2 parts by mass of lucillin TPO (polymerization initiator), 2 parts by mass of byk307, 20 parts by mass of phenoxyethyl acrylate, 60 parts by mass of polyethylene glycol diacrylate, polyethylene The thing containing 10 mass parts of glycol polymers and 3 mass parts of 4-metaoxyphenol was used. Use a high-pressure mercury lamp that emits light at a constant illuminance as a light source for curing the model material and support material, and change the irradiation time by changing the number of scans with a constant sweep speed of the head unit equipped with the light source. I tried to do it. A cube having a side length of 3 [cm] was modeled as a three-dimensional model for evaluation.

  In Experimental Examples 1 to 5, 13, and 14, after the support material was discharged to form the support material region, the support material region was subjected to the first curing process (light energy irradiation process) except for Experimental Example 13. . In this curing treatment, ultraviolet rays with an illuminance of 100 mW / cm 2 (measured with UV POWER PUCK II manufactured by EIT) were irradiated for different times in the range of 0 to 10 seconds. Thereafter, after the model material was discharged to form the model material region, the entire modeling material layer was subjected to a second curing process for 10 seconds to complete the curing. During modeling, the temperature of the modeling stage was kept at 26 ° C., and the ultrasonic wave was turned off. Thereafter, the surface roughness of the final three-dimensional structure from which the support material region was removed was measured. The surface roughness was measured using Surfcom 1400D manufactured by Tokyo Seimitsu. As shown in FIG. 19, the surface roughness of the surface of the three-dimensional structure is set to 1 to 10 μm by variably adjusting the irradiation time of ultraviolet rays in the first curing process (that is, changing the amount of light energy). I was able to make it properly in the range.

  In Experimental Examples 6 to 10, the support material region is formed and the first curing process (light energy irradiation process) is performed in accordance with Experimental Examples 1 to 5, and the support material is discharged to form the support material region. The ultrasonic wave was irradiated for 1 second to the interface part of a material area | region and a support material area | region. An ultrasonic homogenizer manufactured by Nippon Seiki Co., Ltd. was used for ultrasonic irradiation, and ultrasonic waves were applied from a position 2 mm away from the surface of the modeling material layer. Thereafter, in the same procedure as in Experimental Examples 1 to 5, the entire modeling material layer was subjected to the second curing treatment for 10 seconds to complete the curing. When the surface roughness of the final three-dimensional structure from which the support material region was removed was measured, as shown in FIG. 19, the maximum value of the surface roughness was increased to 15 μm. That is, by using ultrasonic waves in combination, diffusion and mixing of the model material and the support material were promoted, and the surface roughness could be further increased. Therefore, as shown in Examples 1 to 10, 13, and 14, it can be confirmed that the surface roughness can be adjusted in a wider range by adjusting the energy amount by the ultrasonic wave in addition to the adjustment of the light energy amount. It was. Further, for example, as is clear from the comparison between Example 1 and Experimental Example 6, after the support material is semi-cured by light irradiation with a predetermined energy amount, the energy amount given by the ultrasonic wave is changed, so that the final result is obtained. It was confirmed that the surface roughness of the three-dimensional structure obtained can be adjusted.

  In Experimental Examples 11 and 12, modeling was performed according to Experimental Example 3 except that the temperature of the modeling stage was kept at another temperature (60 ° C. or 10 ° C.) when forming the modeling material layer. As shown in FIG. 19, when the temperature of the modeling stage is increased, the temperature around the modeling stage changes, the viscosity of the model material and the support material discharged onto the modeling stage decreases, and the model material region and the support material region The diffusion and mixing of both modeling materials at the interface with the surface were promoted, and the surface roughness on the surface of the final three-dimensional model was increased. On the other hand, when the temperature of the modeling stage is lowered, the temperature around the modeling stage is lowered, the viscosity of the model material and the support material discharged onto the modeling stage is increased, and the interface portion between the model material region and the support material region The diffusion and mixing of both modeling materials in the above were suppressed, and the surface roughness on the surface of the final three-dimensional model was reduced. That is, it was confirmed that the surface roughness of the finally obtained three-dimensional structure can be adjusted by changing the temperature around the modeling stage after semi-curing the support material by light irradiation with a predetermined energy amount. .

DESCRIPTION OF SYMBOLS 100 3D modeling apparatus 110 Control part 115 Memory | storage part 120 Head unit 121,129 Housing | casing 122 1st discharge head 124 2nd discharge head 125 Smoothing apparatus 125A Leveling roller 125B Scraping member 125C Recovery member 126,127 Light source Over 128 Sound wave irradiation unit 130 Moving mechanism 132 Main scanning direction guide 134 Sub scanning direction guide 136 Vertical direction guide 140 Modeling stage 145 Display unit 150 Data input unit 155 Computer device 160 Operation unit 170 Ultrasonic irradiation device 180 Peltier element 185 Power source 200 Three-dimensional modeling Object 210 Model material region (first modeling material region)
220 Support material area (second modeling material area)
230 Interface

Claims (11)

A first modeling material region made of an energy curable first modeling material and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling material during modeling and is removed after the modeling is completed. A modeling stage on which a plurality of modeling material layers including a modeling material layer having
A first modeling material region forming unit that discharges the first modeling material to form the first modeling material region;
A second modeling material region forming unit that discharges the second modeling material to form the second modeling material region;
An energy applying device that applies energy to cure at least one of the first modeling material region and the second modeling material region;
A control unit that controls at least the energy application device;
With
The control unit is applied to the one area after the one area is formed and before the other area is formed between the first modeling material area and the second modeling material area. The first modeling material and the second at the interface between the first modeling material region and the second modeling material region, which are formed when the other region is formed by changing the amount of energy to be generated. Adjust the degree of mixing with the modeling material,
A three-dimensional modeling apparatus characterized by this.   The three-dimensional modeling apparatus according to claim 1, wherein the control unit changes the amount of energy by changing a time for applying a predetermined amount of the energy.   The three-dimensional modeling apparatus according to claim 1, wherein the control unit changes the energy amount by changing the intensity of the energy. It further includes an ultrasonic irradiation unit that irradiates ultrasonic waves toward the modeling material layer,
The control unit controls the ultrasonic wave irradiation unit after the interface unit is formed, and changes the intensity of the ultrasonic wave applied to the interface unit in addition to the energy amount. The three-dimensional modeling apparatus according to claim 1, wherein the degree is adjusted. It further includes an ultrasonic irradiation unit that irradiates ultrasonic waves toward the modeling material layer,
The control unit controls the ultrasonic irradiation unit after the interface unit is formed, and changes the irradiation time of the ultrasonic wave applied to the interface unit in addition to the energy amount, thereby mixing the mixing unit. The three-dimensional modeling apparatus according to claim 1, wherein the degree is adjusted. A temperature adjusting unit for adjusting the temperature around the modeling stage;
The control unit adjusts the degree of mixing by controlling the temperature adjusting unit and changing the temperature around the modeling stage in addition to the energy amount after the interface is formed. The three-dimensional modeling apparatus according to any one of claims 1 to 5. The first modeling material and the second modeling material are both photocurable resins,
The three-dimensional modeling apparatus according to any one of claims 1 to 6, wherein the energy applying device applies the energy to the one region by irradiating light.   An information receiving unit that receives information on the surface state of the three-dimensional structure to be modeled is further provided, and the control unit is provided with energy applied to the one region based on the information received by the information receiving unit. The three-dimensional modeling apparatus according to claim 1, wherein the amount is changed. A first modeling material region made of an energy curable first modeling material and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling material and is removed after the modeling is completed. A modeling stage on which a plurality of modeling material layers including a modeling material layer are stacked;
A first modeling material region forming unit that discharges the first modeling material to form the first modeling material region;
A second modeling material region forming unit that discharges the second modeling material to form the second modeling material region;
A first energy applying device that applies first energy for curing one of the first modeling material region and the second modeling material region to at least one region;
A second energy application device that applies second energy to the modeling material layer;
A control unit for controlling at least the first and second energy applying devices;
With
After the one region is formed, the control unit applies the first energy to the one region and semi-cures the first region so as to contact the semi-cured one region. By changing the second amount of energy applied to the interface between the first modeling material region and the second modeling material region after the other of the modeling material region and the second modeling material region is formed. Adjusting the degree of mixing of the first modeling material and the second modeling material at the interface part,
A three-dimensional modeling apparatus characterized by this. Receive information about the surface condition of the 3D object to be modeled,
A first modeling material region made of an energy curable first modeling material, and a second modeling material region made of an energy curable second modeling material that is in contact with the first modeling region during modeling and is removed after the modeling is completed. Forming one region of
Applying an amount of energy adjusted based on the information to the one region to advance curing,
The first modeling material region is formed such that the other one of the first modeling material region and the second modeling material region is in contact with the one region to which energy is applied, and faces the second modeling material region. A three-dimensional modeling method, wherein an interface portion of a material region is brought into a surface state corresponding to the information.   11. The three-dimensional image according to claim 10, wherein each of the first modeling material and the second modeling material is a photocurable resin, and the energy is applied to the one region by irradiating light. Modeling method.

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