JP2016037008A - Method for manufacturing three-dimensional molded article - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a three-dimensional molded article, by which the upper surface of a three-dimensional molded article can be more flattened.SOLUTION: The method for manufacturing a three-dimensional molded article is implemented in an inkjet printer including a discharge unit to discharge an ink and a carriage drive unit to reciprocally move the discharge unit in main scanning directions. The method for manufacturing a three-dimensional molded article includes an enclosure wall setting step, an ink discharging step, and a press-contact curing step. In the enclosure wall setting step, an enclosure wall having the same thickness as that of a layer constituting the three-dimensional molded article is set on a working surface by discharging an ink by the discharge unit that moves in the main scanning directions and irradiating the ink with UV rays. In the ink discharging step, an ink is discharged inside an inner surface of the enclosure wall by the discharge unit that moves in the main scanning directions, on the basis of a feature data of each layer of the three-dimensional molded article. In the press-contact curing step, the ink is exposed to light while a flat surface parallel to the working surface is pressed to the enclosure wall and the ink inside and spaced from the inner surface of the enclosure wall.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a method for manufacturing a three-dimensional structure.

  A three-dimensional printer that forms a three-dimensional structure by laminating formed materials such as ejected ink and a method for manufacturing the three-dimensional structure are known. For example, the three-dimensional printer described in the following Patent Documents 1 and 2 divides the three-dimensional data of a three-dimensional structure into a plurality of layers, and discharges and hardens the modeling material sequentially from the lowermost layer to stack By doing so, a three-dimensional structure that matches the three-dimensional data is formed. These three-dimensional printers include an inkjet head that ejects ink as a modeling material. The three-dimensional printers of Patent Documents 1 and 2 use ultraviolet curable ink as a modeling material, and cure the ultraviolet curable ink by irradiating the ultraviolet curable ink discharged and landed from the curing unit with ultraviolet rays. Let

Japanese Patent No. 4420585 JP 2013-067036 A

  By the way, in the three-dimensional printers of Patent Documents 1 and 2 described above, a three-dimensional structure is formed by, for example, ejecting ink from the head while moving the head in the main scanning direction and overlapping the ejected ink droplets. Since modeling is performed, the upper surface of the three-dimensional model may not be flat.

  This invention is made | formed in view of the above, Comprising: It aims at providing the manufacturing method of the three-dimensional structure which can make the upper surface of a three-dimensional structure more flat.

  In order to solve the above-described problems and achieve the object, the method for manufacturing a three-dimensional structure according to the present invention includes a discharge unit that discharges ink whose degree of cure changes when an external stimulus is applied to a work surface. And a reciprocating unit that reciprocates the ejection unit in the main scanning direction, and a method for producing a three-dimensional structure to be executed in a three-dimensional printer that applies an external stimulus to the ink ejected to the work surface The reciprocating unit moves the ejection unit in the main scanning direction, and the ejection unit ejects ink to give an external stimulus to the same thickness as the layer constituting the three-dimensional structure. An enclosure wall installation step of installing the formed enclosure wall on the work surface; and after the enclosure wall installation step, the reciprocating movement unit moves the ejection unit in the main scanning direction, while the ejection unit moves the enclosure. 3D modeling inside the inner wall An ink ejection step for ejecting ink based on the shape data for each layer of the ink and a flat surface parallel to the work surface on the enclosure wall and the ink spaced inward from the inner surface of the enclosure wall after the ink ejection step A pressure-curing step of pressing the surface and applying an external stimulus to the ink to completely cure the ink.

  In this invention, ink is ejected to the inside of the enclosure wall formed to the same thickness as the layer constituting the three-dimensional structure, and the flat surface of the press-contact portion parallel to the work surface is located on the inner side of the inner surface of the enclosure wall. Press against ink. For this reason, in the three-dimensional printer, the landing position of the first ink droplet ejected from the ejection section is closer to the landing position of the rear droplet, and the cured ink ejection section moves in the moving direction. Even when the upstream end is thicker than the downstream end, the upper surface of the layer constituting the three-dimensional structure can be formed flat, and the upper surface of the three-dimensional structure can be flattened. .

  Moreover, in the manufacturing method of the three-dimensional structure, in the press-curing step, a film having flexibility is interposed between the press-contact portion and the work surface, and the film is placed between the enclosure wall and the enclosure wall. The ink may be pressed against the ink separated from the inner surface.

  In this invention, since the flexible film is sent out between the press contact portion and the work surface, the flexible film is pressed against the ink when the ink is pressed at the press contact portion. Therefore, the layer constituting the three-dimensional structure, that is, the upper surface of the three-dimensional structure can be made flat as much as the surface of the flexible film. Further, by moving the flexible film as the layer is formed, a flat surface on which the ink is not attached to the film can be pressed against the ink, and the layer constituting the three-dimensional structure, that is, The upper surface of the three-dimensional structure can be formed flat.

  Moreover, in the manufacturing method of the said three-dimensional structure, the said enclosure wall installation process, the said ink discharge process, and the said pressure-contact hardening process shall be repeated in multiple times.

  In this invention, since the surrounding wall installation process, the ink discharge process, and the pressure-curing curing process are repeated a plurality of times, the upper surface of each layer constituting the three-dimensional structure can be flattened, and various thicknesses of the three-dimensional structure Can be formed.

  Further, in the method for producing a three-dimensional structure, in the ink ejection step, an external stimulus weaker than an external stimulus that is completely cured is applied to ink that is spaced inward from the inner surface of the enclosure wall, or An external stimulus may be applied for a time shorter than the time for complete curing.

  In the present invention, in the ink discharge process, the external stimulus that is weaker than the external stimulus that completely cures or the external stimulus that is shorter than the complete cure is applied to the ink ejected inside the enclosure wall. The ink pressed against the pressure contact portion is in a semi-cured state. For this reason, even if it presses a press-contact part, it can suppress that an ink loses shape and can form the three-dimensional structure of a desired shape.

  In the method of manufacturing a three-dimensional structure, in the ink discharge step, the reciprocating unit discharges ink while moving the discharge unit a plurality of times in the main scanning direction, and the reciprocating movement. Each time the unit moves the ejection unit in the main scanning direction, the external stimulus may be applied to the ink that is spaced inward from the inner surface of the surrounding wall.

  In this invention, every time the reciprocating unit moves the ejection unit in the main scanning direction in the ink ejection process, the external stimulus is weaker than the external stimulus that completely cures to the ink inside the enclosure wall, or is completely cured. Apply external stimuli for a shorter period of time. For this reason, the ink which is discharged in the ink discharging step and constitutes each layer of the three-dimensional structure can be semi-cured more uniformly, and a three-dimensional structure having a desired shape can be formed.

  The manufacturing method of the three-dimensional structure according to the present invention has an effect that the upper surface of the three-dimensional structure can be flattened.

FIG. 1 is a schematic configuration diagram illustrating a schematic configuration of an inkjet printer according to an embodiment. FIG. 2 is a perspective view showing an example of a three-dimensional structure formed by the ink jet printer shown in FIG. FIG. 3 is an example of a flowchart of a method for manufacturing a three-dimensional structure using the inkjet printer according to the embodiment. FIG. 4 is an explanatory diagram for explaining the trajectory of ink droplets ejected by the ink jet printer shown in FIG. FIG. 5 is an explanatory diagram for explaining the shape of the upper surface of a three-dimensional structure formed by ink droplets discharged by the ink jet printer shown in FIG. FIG. 6 is a perspective view showing an enclosure wall and a three-dimensional structure formed by the ink jet printer shown in FIG. 7 is a cross-sectional view in the main scanning direction showing an enclosure wall or the like formed by the ink jet printer shown in FIG. FIG. 8 is a cross-sectional view in the main scanning direction showing a state where ink for forming each layer of the three-dimensional structure is ejected inside the enclosure wall shown in FIG. FIG. 9 is a cross-sectional view in the main scanning direction showing a state in which the press contact portion and the film are positioned above the ink forming each layer of the three-dimensional structure shown in FIG. FIG. 10 is a cross-sectional view in the main scanning direction showing a state in which the press contact portion is pressed against the ink forming each layer of the three-dimensional structure shown in FIG. FIG. 11 is a cross-sectional view in the main scanning direction showing a state in which the next enclosure wall is formed on the enclosure wall shown in FIG. FIG. 12 is a cross-sectional view in the main scanning direction showing an enclosure wall of an inkjet printer according to a modification of the embodiment of the present invention.

  Hereinafter, an embodiment of a method for manufacturing a three-dimensional structure according to the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited by this embodiment. In addition, constituent elements in the following embodiments include those that can be easily replaced by those skilled in the art or those that are substantially the same.

Embodiment
FIG. 1 is a schematic configuration diagram illustrating a schematic configuration of an inkjet printer according to an embodiment. FIG. 2 is a perspective view showing an example of a three-dimensional structure formed by the ink jet printer shown in FIG. FIG. 3 is an example of a flowchart of a method for manufacturing a three-dimensional structure using the inkjet printer according to the embodiment. FIG. 4 is an explanatory diagram for explaining the trajectory of ink droplets ejected by the ink jet printer shown in FIG. FIG. 5 is an explanatory diagram for explaining the shape of the upper surface of a three-dimensional structure formed by ink droplets discharged by the ink jet printer shown in FIG. FIG. 6 is a perspective view showing an enclosure wall and a three-dimensional structure formed by the ink jet printer shown in FIG.

  An inkjet printer 1 as a three-dimensional printer according to the embodiment shown in FIG. 1 uses a so-called inkjet method to manufacture a three-dimensional structure W (an example is shown in FIG. 2) that is a three-dimensional three-dimensional object. It is a modeling device. The inkjet printer 1 typically divides the three-dimensional structure W into a number of layers LY (shown in FIG. 2) in the vertical direction based on the three-dimensional data of the three-dimensional structure W, and the three-dimensional Based on the shape data of each layer LY of the modeled object W, a three-dimensional modeled object W that matches the three-dimensional data is obtained by sequentially stacking modeling materials (thickened ink) from the lower layer LY. Is formed. The three-dimensional structure W shown as an example in FIG. 2 is formed in a rectangular parallelepiped shape. However, in the present invention, the shape of the three-dimensional structure W is not limited to this. Moreover, the inkjet printer 1 can model a plurality of three-dimensional structures W at a time, as shown in FIG. In the case shown in FIG. 6, the plurality of three-dimensional structures W have the same shape. However, the present invention is not limited to this, and a plurality of three-dimensional structures W having different shapes may be formed.

  As shown in FIG. 1, the ink jet printer 1 includes a mounting table 2 whose upper surface forms a work surface 2a, a Y bar 3 provided in the main scanning direction, a carriage 4, and a carriage driving unit 5 (corresponding to a reciprocating movement unit). And a mounting table drive unit 6, a press contact unit 9, a film delivery unit 10, a press contact drive unit 11, a control unit 7, an input device 8, and the like.

  The work surface 2a of the mounting table 2 is formed flat in a horizontal direction (a direction parallel to both the X axis and the Y axis shown in FIG. 1), and ink as a modeling material is formed thereon from the lower layer LY. It is a plane laminated in order. The mounting table 2 is formed in a substantially rectangular shape, for example, but is not limited thereto.

  The Y bar 3 is provided at a predetermined interval above the mounting table 2 in the vertical direction. The Y bar 3 is provided linearly along the main scanning direction parallel to the horizontal direction (Y axis). The Y bar 3 guides the reciprocation of the carriage 4 along the main scanning direction.

  The carriage 4 is held by the Y bar 3 and can reciprocate along the Y bar 3 in the main scanning direction. The carriage 4 is controlled to move in the main scanning direction. The carriage 4 is provided with a discharge unit 41 and an ultraviolet irradiator 42 (corresponding to an exposure unit) on a surface facing the mounting table 2 in the vertical direction via a holder or the like (not shown).

  The ejection part 41 is capable of ejecting ink as a modeling material whose degree of cure changes when an external stimulus is applied to the work surface 2 a, and can be moved in the main scanning direction by being provided on the carriage 4. Is. The discharge part 41 of embodiment discharges the ink which forms the three-dimensional structure W as an ink from which the degree of hardening changes by exposing as external stimulus. The discharge section 41 includes a plurality of discharge nozzles (not shown) that are provided on the carriage 4 and that can discharge ink stored in an ink tank (not shown) onto the work surface 2a. The plurality of discharge nozzles are arranged along the longitudinal direction of the Y bar 3, that is, the main scanning direction.

  The ejection unit 41 can reciprocate along the main scanning direction as the carriage 4 moves along the main scanning direction. The discharge nozzle of the discharge unit 41 is connected to an ink tank through various ink flow paths, a regulator, a pump, and the like. One or a plurality of discharge nozzles of the discharge unit 41 are provided according to the number of ink tanks, in other words, the number of types of ink that can be printed simultaneously. The discharge nozzle of the discharge unit 41 is an ink jet head that can discharge ink in the ink tank toward the work surface 2a by an ink jet method. Here, for example, UV (ultraviolet) curable ink that is cured by irradiating ultraviolet rays can be used as the ink whose degree of curing changes by exposure. For example, the color of the three-dimensional structure W to be manufactured can be used. Accordingly, white ink, colored ink, transparent ink, and the like can be used as appropriate. The discharge unit 41 is electrically connected to the control unit 7, and the driving of the discharge unit 41 is controlled by the control unit 7. In the present invention, as an ink whose degree of cure changes when an external stimulus discharged from the ejection unit 41 is applied, an ink whose degree of cure changes (hardens) when heated as an external stimulus is used. Also good. Moreover, the discharge part 41 also has an enclosure wall installation part that can install an enclosure wall E formed in the same thickness as the layer LY constituting the three-dimensional structure W on the work surface 2a.

  The ultraviolet irradiator 42 gives an external stimulus to the ink I (shown in FIG. 8) ejected onto the work surface 2a. The ultraviolet irradiator 42 can be exposed by irradiating the ink I discharged onto the work surface 2a with ultraviolet rays. The ultraviolet irradiator 42 is constituted by, for example, an LED module that can irradiate ultraviolet rays. The ultraviolet irradiator 42 is provided on the carriage 4 and can reciprocate along the main scanning direction as the carriage 4 moves along the main scanning direction. The ultraviolet irradiator 42 is electrically connected to the control unit 7, and its driving is controlled by the control unit 7.

  The carriage driving unit 5 is a driving device that reciprocally moves the carriage 4, that is, the discharge unit 41 relative to the Y bar 3 in the main scanning direction. The carriage drive unit 5 includes, for example, a transmission mechanism such as a conveyance belt connected to the carriage 4 and a drive source such as an electric motor that drives the conveyance belt, and transmits power generated by the drive source via the transmission mechanism. Thus, the power is converted into power for moving the carriage 4 along the main scanning direction, and the carriage 4 is reciprocated along the main scanning direction. The carriage drive unit 5 is electrically connected to the control unit 7, and the drive is controlled by the control unit 7.

  As shown in FIG. 1, the mounting table driving unit 6 includes a vertical direction moving unit 61, a sub-scanning direction moving unit 62, and an axis rotation unit 63. The vertical movement unit 61 moves the mounting table 2 up and down along a vertical direction parallel to the Z axis, so that the work surface 2 a formed on the mounting table 2 is relatively vertical with respect to the discharge unit 41. It moves up and down along. Thereby, the mounting table drive unit 6 can move the work surface 2a closer to and away from the discharge unit 41, the ultraviolet irradiator 42, and the like along the vertical direction. That is, the mounting table drive unit 6 can move the work surface 2 a relative to the discharge unit 41 and the ultraviolet irradiator 42 along the vertical direction.

  The sub-scanning direction moving unit 62 moves the mounting table 2 in the sub-scanning direction parallel to the X axis orthogonal to the main scanning direction, so that the work surface 2a formed on the mounting table 2 is moved with respect to the discharge unit 41. Relatively reciprocating along the sub-scanning direction. Thereby, the mounting table drive unit 6 can reciprocate the work surface 2a along the sub-scanning direction with respect to the discharge unit 41, the ultraviolet irradiator 42, and the like. That is, the sub-scanning direction moving unit 62 can relatively reciprocate the discharge unit 41, the ultraviolet irradiator 42, and the work surface 2a in the sub-scanning direction. In the embodiment, the sub-scanning direction moving unit 62 moves the mounting table 2 in the sub-scanning direction. However, in the present invention, the Y-bar 3, the discharge unit 41, and the ultraviolet irradiator 42 are not limited to this. It may be moved in the sub-scanning direction.

  The axis rotation unit 63 rotates the mounting table 2 around an axis (Z axis) parallel to the vertical direction, so that the work surface 2 a formed on the mounting table 2 is relatively axial with respect to the discharge unit 41. It rotates around the heart. Thereby, the mounting table drive unit 6 can rotate the work surface 2a around the axis with respect to the discharge unit 41, the ultraviolet irradiator 42, and the like. That is, the axis rotation unit 63 makes the discharge unit 41, the ultraviolet irradiator 42, and the work surface 2a rotatable about an axis parallel to the vertical direction.

  The pressure contact portion 9 is capable of pressing a flat surface 9a parallel to the work surface 2a against the ink I ejected on the work surface 2a. The pressure contact portion 9 is formed in a thick flat plate shape, and a window 9b (shown in FIG. 1) made of transparent glass or plastic that transmits ultraviolet rays is provided at the center. The press contact portion 9 has a flat surface 9a formed on the lower side thereof in parallel with the work surface 2a and formed by the surface of the window 9b. The flat surface 9a is formed in a size substantially equal to the work surface 2a.

  The film delivery part 10 sends out the flexible film F (shown in FIG. 9) between the press contact part 9 and the work surface 2a. As shown in FIG. 9, the film delivery unit 10 includes a driving roller 101 that is rotated around an axis by a motor (not shown), and a driven roller that is provided in parallel with the driving roller 101 at an interval and is rotatable. 102, and a flexible film F spanned between the driving roller 101 and the driven roller 102.

  The distance between the driving roller 101 and the driven roller 102 is substantially equal to the size of the work surface 2a. The film F is made of a material that can transmit ultraviolet rays. The film F is formed so that its width is substantially equal to the width of the work surface 2a. The film F is wound around the outer periphery of the driven roller 102 and wound around the outer periphery of the driving roller 101. The film F is rotated in the direction in which the driving roller 101 is wound by a motor or the like, so that the film F is fed from the driven roller 102 between the pressure contact portion 9 and the work surface 2 a and is wound on the driving roller 101. As a material constituting the film F, it is desirable to use a material having low adhesion to the ink I. As a material constituting the film F, for example, PP (polypropylene) can be used. The film delivery unit 10 is electrically connected to the control unit 7 and its drive is controlled by the control unit 7.

  The pressure contact drive unit 11 is a drive device that moves the pressure contact unit 9 and the film delivery unit 10 in the horizontal direction over the work surface 2a and a position retracted from above. The pressure contact drive unit 11 is a drive device that moves the pressure contact unit 9 and the film delivery unit 10 in the Z-axis direction above the work surface 2a so as to approach or separate from the work surface 2a. The press contact driving unit 11 is electrically connected to the control unit 7, and its driving is controlled by the control unit 7.

  The control unit 7 controls each unit of the inkjet printer 1 including the discharge unit 41, the ultraviolet irradiator 42, the carriage driving unit 5, the mounting table driving unit 6, the film delivery unit 10, the press contact driving unit 11, and the like. The control unit 7 surrounds the three-dimensional structure W on the work surface 2a and, after installing the enclosure wall E formed in the same thickness as each layer LY constituting the three-dimensional structure W, from the inner surface of the enclosure wall E Also, the uncured layer LY of the three-dimensional structure W is composed of the ink I that is ejected from the ejection portion 41 that moves inward in the main scanning direction and that has the same thickness as the surrounding wall E and that is spaced inward from the inner surface. Form. Thereafter, the controller 7 presses the flat surface 9a of the pressure contact portion 9 against the surrounding wall E and the uncured layer LY made of the ink I ejected inside the surrounding wall E, and then from the ultraviolet irradiator 42. The three-dimensional structure W is formed by irradiating ultraviolet rays to completely cure the uncured layer LY.

  The control unit 7 includes hardware such as an arithmetic device and a memory, and a program that realizes these predetermined functions. The control unit 7 controls the discharge unit 41 to control the discharge amount, discharge timing, discharge period, and the like of ink (modeling ink). The control unit 7 controls the ultraviolet irradiator 42 to control the intensity of ultraviolet light to be irradiated, the exposure timing, the exposure period, and the like. The control unit 7 controls the carriage driving unit 5 to control the relative movement of the carriage 4 along the main scanning direction. The control unit 7 controls the mounting table driving unit 6 to control the relative movement of the mounting table 2 along the vertical direction and the sub-scanning direction and the relative movement around the axis. The control unit 7 controls the film delivery unit 10 to control the delivery amount, delivery timing, etc. of the film F. The control unit 7 controls the press contact driving unit 11 to control the press contact force, the press contact timing, the press contact period, and the like of the press contact unit 9.

  Here, of the ink droplets P (shown in FIG. 4) ejected from the ejection unit 41 while being moved in the main scanning direction, the leading droplet Pa is determined by the movement speed of the ejection unit 41 and the ejection from the ejection unit 41. Although it is discharged at a speed combined with the speed, it is decelerated because it receives air resistance. On the other hand, the ink drop Pb on the rear side is located behind the ink drop Pa on the front side, the air resistance is suppressed, and the deceleration is suppressed.

  Therefore, in the drop trajectories M and Ma of the ink droplets Pa and Pb, as shown by solid lines in FIGS. 4 and 5, the landing position of the droplet Pa located on the head side on the work surface 2a or the like is on the rear side. It will be closer to each other than the landing position of the positioned drop Pb. In the example shown in FIG. 4, the locus M of the ink droplets Pa and Pb ejected from the ejection unit 41 while moving the ejection unit 41 to the right in the figure is shown by a solid line, and the leading droplet Pa is on the rear side. The trajectory Ma when falling along the same trajectory M as the droplet Pb is indicated by a dotted line.

  Further, when the three-dimensional structure W is formed while the landing position of the droplet Pa positioned on the head side on the work surface 2a or the like is close to the landing position of the droplet Pb positioned on the rear side, a one-dot chain line in FIG. As shown, in the upper surface Wa of the three-dimensional structure W formed with ink, the end Wb formed by the leading droplet Pa rises more than the other parts, and the upper surface Wa extends from the end Wb in one direction R. It is formed so as to gradually become lower as it goes downstream. The manufacturing method of the inkjet printer 1 and the three-dimensional structure according to the present embodiment suppresses the end portion Wb of the three-dimensional structure W from rising above other parts, and the upper surface of each layer LY of the three-dimensional structure W. Wa is formed flat to form a three-dimensional structure W having a desired three-dimensional shape.

  The input device 8 is connected to the control unit 7 and inputs three-dimensional data related to the shape of the three-dimensional structure W. The input device 8 includes, for example, a PC connected to the control unit 7 by wire / wireless, various terminals, and the like.

  Next, an example of a method for manufacturing a three-dimensional structure using the inkjet printer 1 described above will be described with reference to the flowchart of FIG. The method for manufacturing the three-dimensional structure shown in FIG. 3 is executed in the control unit 7 of the inkjet printer 1. In the description of FIG. 3, FIGS. 7 to 11 are also referred to as appropriate. 7 is a cross-sectional view in the main scanning direction showing an enclosure wall or the like formed by the ink jet printer shown in FIG. FIG. 8 is a cross-sectional view in the main scanning direction showing a state where ink for forming each layer of the three-dimensional structure is ejected inside the enclosure wall shown in FIG. FIG. 9 is a cross-sectional view in the main scanning direction showing a state in which the press contact portion and the film are positioned above the ink forming each layer of the three-dimensional structure shown in FIG. FIG. 10 is a cross-sectional view in the main scanning direction showing a state in which the press contact portion is pressed against the ink forming each layer of the three-dimensional structure shown in FIG. FIG. 11 is a cross-sectional view in the main scanning direction showing a state in which the next enclosure wall is formed on the enclosure wall shown in FIG.

  The manufacturing method of the three-dimensional structure according to the embodiment includes a shape data generation process (step ST1), an ejection pattern generation process (step ST2), an enclosure wall installation process (step ST3), and an ink ejection process (step ST4). , Including a pressure-curing process (step ST5) and a moving process (step ST7), an enclosure wall setting process (step ST3), an ink ejection process (step ST4), a pressure-curing process (step ST5), and a moving process. The three-dimensional structure W is manufactured by repeatedly executing (Step ST7) one or more times, that is, a plurality of times and printing for each layer LY. The shape data generation step (step ST1), the discharge pattern generation step (step ST2), the surrounding wall installation step (step ST3), the ink discharge step (step ST4), the pressure curing step (step ST5), and the transfer step ( Step ST7) is performed by controlling the drive of each part of the inkjet printer 1 by the control unit 7 of the inkjet printer 1.

  In the three-dimensional structure manufacturing method of the present embodiment, first, the control unit 7 generates shape data for each layer LY of the three-dimensional structure W as a shape data generation step (step ST1). In this case, the control unit 7 forms the shape of the three-dimensional structure W for each layer LY having a desired thickness along the vertical direction based on the three-dimensional data regarding the shape of the three-dimensional structure W input from the input device 8. Calculate and generate data. Furthermore, the control unit 7 generates three-dimensional data related to the shape of the enclosure wall E that can surround the three-dimensional structure W. The control unit 7 forms the enclosure wall E in a lattice shape, sets the distance from the three-dimensional structure W to the inner surface of the enclosure wall E as a predetermined distance, and the thickness of the enclosure wall E defines the three-dimensional structure W. Three-dimensional data of each enclosure wall E is generated so as to be equal to the thickness of each layer LY that constitutes the layer. That is, the same number of enclosure walls E as the layers LY constituting the three-dimensional structure W are provided and correspond to the layers LY constituting the three-dimensional structure W on a one-to-one basis. Note that the width of the enclosure wall E in the main scanning direction and the sub-scanning direction is much smaller than the width of the three-dimensional structure W, and the above-described rising of the end portion Wb on the upper surface Wa does not affect the dimensional accuracy (almost). Width).

  Next, the control unit 7 generates a print pattern for each layer LY of the three-dimensional structure W as a discharge pattern generation step, a discharge control amount that can realize the generated print pattern, an exposure control amount, and a carriage drive unit. 5. The control amount of the mounting table driving unit 6, the film delivery unit 10, and the pressure contact driving unit 11 is generated (step ST2). Further, the control unit 7 generates a print pattern for each enclosure wall E in the discharge pattern generation step, and performs a discharge control amount, an exposure control amount, a carriage drive unit 5 and a mounting table drive capable of realizing the generated print pattern. A control amount of the unit 6 is generated.

  Next, as an enclosure wall installation step, as illustrated in FIG. 7, the enclosure wall E formed with the same thickness as the layer LY constituting the three-dimensional structure W is used as the work surface 2 a or the already installed enclosure wall E. Install on top. In this case, the control unit 7 controls the discharge unit 41, the ultraviolet irradiator 42, and the like, and the carriage drive unit 5 relatively moves the discharge unit 41 and the ultraviolet irradiator 42 in the main scanning direction according to the generated discharge pattern. The ejection unit 41 ejects ink onto the work surface 2a while moving the mounting table 2 relatively in the sub-scanning direction and the vertical direction, and relatively rotating around the axis. Enclose wall installation control is performed (step ST3) in which an external stimulus is applied (exposure) to the ejected ink to install the enclosure wall E on the work surface 2a.

  Specifically, the control unit 7 controls the press contact driving unit 11 to retract the film delivery unit 10 and the press contact unit 9 from the work surface 2a, and the carriage drive unit 5, the vertical direction moving unit 61, and the axis rotation unit. 63 is controlled to position the carriage 4 at an appropriate position with respect to the work surface 2a. Then, the control unit 7 moves the carriage 4 to the carriage driving unit 5 in the main scanning direction, and discharges the discharge nozzles of the discharge unit 41 at an appropriate timing to form each enclosure wall E generated in the discharge pattern generation process. Ink is ejected from the ultraviolet rays and ultraviolet rays are emitted from the ultraviolet irradiator 42. The discharged ink lands on the work surface 2a or the shaped enclosure wall E and is cured. Then, the control unit 7 ejects ink from the ejection unit 41 while exposing the ejected ink while moving the carriage 4 at least once in the main scanning direction by the control amount of the carriage 4 generated in the ejection pattern generation process. Then, it is completely cured to form one line of the enclosure wall E in the main scanning direction. Then, the control unit 7 controls the sub-scanning direction moving unit 62 to move the mounting table 2 in the sub-scanning direction by one line, and then repeats the previous step, as shown in FIG. Model the whole of E. In this way, the ink jet printer 1 is provided with the surrounding wall E formed on the work surface 2a and having the same thickness as the layer LY constituting the three-dimensional structure W by discharging and exposing ink. .

  As illustrated in FIG. 8, the control unit 7, as illustrated in FIG. 8, after the enclosure wall installation step (step ST <b> 3), the carriage drive unit 5 moves the ejection unit 41 in the main scanning direction while the ejection unit 41 is moved. Ink is ejected on the inner side of the inner surface of the enclosure wall E of the work surface 2a based on the shape data for each layer LY of the three-dimensional structure W (step ST4). In this case, the control unit 7 controls the discharge unit 41 to change the shape data for each layer LY of the three-dimensional structure W from the discharge unit 41 moving in the main scanning direction to the inner side of the enclosure wall E of the work surface 2a. Based on this, ink ejection control for ejecting ink is executed. Specifically, the control unit 7 controls the carriage driving unit 5, the vertical direction moving unit 61, and the axial center rotating unit 63 to place the carriage 4 at appropriate positions where each layer LY can be formed on the work surface 2a. Position.

  Then, the control unit 7 moves the carriage 4 to the carriage drive unit 5 in the main scanning direction, and discharges the discharge unit at an appropriate timing to form each layer LY of the three-dimensional structure W generated in the discharge pattern generation process. Ink is discharged from the 41 discharge nozzles to the inner side of the inner surface of the surrounding wall E. The ejected ink I lands on the work surface 2a or the layer LY that has been shaped. Then, the control unit 7 ejects ink from the ejection unit 41 while moving the carriage 4 one or more times in the main scanning direction by the control amount of the carriage 4 generated in the ejection pattern generation process, One line in the main scanning direction of each layer LY composed of the uncured ink I constituting the three-dimensional structure W having the same thickness is formed. In the present invention, in the ink ejection step, the ejection unit 41 may eject ink while the carriage driving unit 5 moves the ejection unit 41 a plurality of times in the main scanning direction. Then, the control unit 7 controls the sub-scanning direction moving unit 62 to move the mounting table 2 by one line in the sub-scanning direction, and then repeats the previous steps to obtain a three-dimensional display as shown in FIG. The entire layer LY composed of the uncured ink I of the model W is formed.

  In the ink discharge process, the control unit 7 is configured so that the ultraviolet irradiator 42 is externally applied to ink separated from the inner surface of the surrounding wall E every time the carriage drive unit 5 moves the discharge unit 41 in the main scanning direction or during the movement. A stimulus is given (exposure). At this time, the ultraviolet irradiator 42 gives an external stimulus (exposure) weaker than the external stimulus (exposure) that is completely cured to the ink spaced inward from the inner surface of the enclosure wall E, or is completely cured. An external stimulus is applied (exposure) for a time shorter than the time required to semi-cure the ink ejected in the ink ejection process. It is desirable that the irradiation time of the ultraviolet rays at this time is such a time that the upper surface of each layer LY can be formed flat when the press contact portion 9 is pressed against the upper surface of each layer LY made of ink I.

  Next, as shown in FIG. 9, the control unit 7 controls the press contact driving unit 11 to place the film delivery unit 10 and the press contact unit 9 on the work surface 2a. At this time, the surface of the film F that has never been pressed against the ink I is located above the surrounding wall E and each layer LY of the three-dimensional structure W, and the press contact portion 9 is The film F is positioned above the film F with a gap. And the control part 7 interposes the film F which has flexibility between the press-contact part 9 and the work surface 2a after an ink discharge process (step ST4) as illustrated in FIG. 10 as a press-contact hardening process. Thus, the flat surface 9a parallel to the work surface 2a is pressed against the enclosure wall E and the ink I spaced inward from the inner surface of the enclosure wall E. In this case, after the ink discharge control, the control unit 7 controls the press contact portion 9 and the like, and executes press contact control to press the flat surface 9a against the surrounding wall E and the ink I that is spaced inward from the inner surface of the surrounding wall E. Specifically, the control unit 7 controls the press contact driving unit 11 to lower the film delivery unit 10 and the press contact unit 9, and as shown in FIG. 10, the press contact unit 9 and the work surface 2 a The flexible film F is sent out between the wall F and the flat surface 9a of the press contact portion 9 to press the film F against the surrounding wall E and the ink I spaced away from the inner surface of the surrounding wall E.

  Further, the control unit 7 controls the carriage driving unit 5 and the mounting table driving unit 6 to transmit the ultraviolet rays from the ultraviolet irradiator 42 moving in the main scanning direction and the sub-scanning direction to the entire layers LY of the three-dimensional structure W. Irradiation is given through the window 9b, and the ink I spaced inward from the inner surface of the enclosure wall E is completely cured to form each layer LY of the three-dimensional structure W (step ST5). Then, the control unit 7 controls the pressure contact driving unit 11 and the like to raise the film delivery unit 10 and the pressure contact unit 9, and then controls the film delivery unit 10 to press the drive roller 101 against the ink of the film F. The wound portion is wound up, and the pressure contact drive unit 11 and the like are controlled to retract the film delivery unit 10 and the pressure contact unit 9 from above the work surface 2a.

  Next, it is determined whether or not the formation of the three-dimensional structure W has been completed (step ST6). In this case, the control part 7 is the shape for every layer LY of the three-dimensional structure W produced | generated by the three-dimensional data regarding the shape of the three-dimensional structure W input from the input device 8, or a shape data generation process (step ST1). Based on the data or the like, it is determined whether or not the formation of the three-dimensional structure W has been completed.

  When it is determined that the formation of the three-dimensional structure W has not been completed (step ST6: No), the work surface 2a is separated from the carriage 4 along the vertical direction after the press-curing and curing step (step ST5) as the moving step. Is moved to the side by one layer LY (step ST7), the process returns to step ST3, and the steps after step ST3 are repeatedly executed. In this case, the control unit 7 controls the mounting table driving unit 6 of the mounting table 2 after the pressure control, and moves relative to the work surface 2a away from the carriage 4 along the vertical direction, here, the lower side in the vertical direction. The movement control to be executed is executed. Then, as illustrated in FIG. 11, the control unit 7 performs an enclosure wall installation process (step ST3) by enclosure wall installation control for the next layer (here, the second layer), an ink ejection process (step ST3) by ink ejection control. ST4), a pressure hardening process by pressure control (step ST5), and a movement process by movement control (step ST7) are repeated to sequentially form each layer LY from the lower layer LY of the three-dimensional structure W.

  When the control unit 7 determines that the formation of the three-dimensional structure W has been completed (step ST6: Yes), the worker or the like removes the enclosure wall E from the work surface 2a, and the three-dimensional embodiment of the embodiment. The manufacturing method of a molded article is complete | finished.

  The inkjet printer 1 according to the above embodiment and the method for manufacturing a three-dimensional structure are on the inner side of the inner surface of the enclosure wall E formed to have the same thickness as the layer LY of the three-dimensional structure W to be formed. The ink I is discharged, and the flat surface 9a of the pressure contact portion 9 parallel to the work surface 2a is pressed against the surrounding wall E and the ink I separated from the inner surface of the surrounding wall E. For this reason, in the inkjet printer 1, the landing position of the leading ink droplet Pa ejected from the ejection section 41 is closer to the landing position of the rear droplet Pb, and the ink I ejection section 41 moves. Even if the upstream end Wb in the direction becomes thicker than the other parts, the upper surface of each layer LY made of the ink I can be formed flat, and the upper surface Wa of the three-dimensional structure W can be flattened. In addition, the three-dimensional structure W can be formed into a desired three-dimensional shape.

  Moreover, since the inkjet printer 1 and the manufacturing method of a three-dimensional structure send out the flexible film F between the press contact part 9 and the work surface 2a, when pressing the ink I at the press contact part 9, The film F is pressed against the ink I. Therefore, each layer LY, that is, the upper surface Wa of the three-dimensional structure W can be made flat as much as the surface of the film F. Further, by moving the film F from the lower side in accordance with the formation of the layer LY, the flat surface to which the ink I of the film F is not attached can be pressed against the ink I, and each layer LY, that is, three-dimensional The upper surface Wa of the shaped article W can be formed flat.

  In the ink jet process, the inkjet printer 1 and the method for manufacturing a three-dimensional structure irradiate ultraviolet rays that are weaker than the ultraviolet rays (external stimulus) that are completely cured by the ink ejected inside the inner surface of the enclosure wall E. (Applying external stimulus) or irradiating ultraviolet rays (applying external stimulus) for a shorter time than completely curing, so that the ink I pressed against the pressure contact portion 9 is in a semi-cured state. For this reason, even if it presses the press-contact part 9, it can suppress that the ink I loses shape, and can form the three-dimensional structure W of a desired shape.

  Moreover, since the inkjet printer 1 and the manufacturing method of a three-dimensional structure form the surrounding wall E by ejecting the ink I and irradiating it with ultraviolet rays and curing it, the surrounding wall E having the same thickness as the layer LY is formed. The thickness of each layer LY can be formed to a desired thickness.

  In the inkjet printer 1 and the manufacturing method of the three-dimensional structure, the enclosure wall installation process, the ink discharge process, and the pressure-curing process are repeated a plurality of times, so that the upper surface of each layer LY constituting the three-dimensional structure W is flattened. In addition, the three-dimensional structure W having various thicknesses can be formed.

  The ink jet printer 1 and the method for manufacturing a three-dimensional structure are the inks that are separated from the inner surface of the enclosure wall E every time the carriage driving unit 5 moves the ejection unit 41 in the main scanning direction in the ink ejection process. I is irradiated with an ultraviolet ray weaker than an ultraviolet ray that is completely cured (external stimulus) (external stimulus is applied), or is irradiated with an ultraviolet ray for a shorter period of time (applied an external stimulus) than completely cured. For this reason, the inkjet printer 1 and the method for manufacturing a three-dimensional structure can more uniformly and semi-harden the ink I that is discharged in the ink discharge process and constitutes each layer LY of the three-dimensional structure W. A three-dimensional structure W having a shape of can be formed.

[Modification]
In the above-described embodiment, the ink I is ejected and exposed to form the surrounding wall E. However, the present invention is not limited to this. For example, as shown in FIG. 12, the enclosure wall E-1 is provided so as to protrude upward and downward from the work surface 2a, and before forming each layer LY of the three-dimensional structure W, the enclosure wall E-1 is formed. The thickness of each layer LY may protrude upward from the work surface 2a. FIG. 12 is a cross-sectional view in the main scanning direction showing an enclosure wall of an inkjet printer according to a modification of the embodiment of the present invention. In FIG. 12, the same parts as those of the embodiment are denoted by the same reference numerals, and the description thereof is omitted.

  The inkjet printer 1 and the method for manufacturing a three-dimensional structure shown in FIG. 12 can form the top surface of the three-dimensional structure W flatly, as in the embodiment, and can form a three-dimensional shape into a desired three-dimensional shape. An object W can be formed.

  In addition, the inkjet printer 1 of the present invention may include a discharge unit for forming the enclosure wall E in addition to the discharge unit 41 that discharges ink for forming the three-dimensional structure W. In this case, as the ink ejected by the ejection part forming the enclosure wall E, a support ink having easy water solubility, easy alcohol solubility, or heat solubility after curing may be ejected. In this case, the enclosure wall E can be quickly removed after the three-dimensional structure W is formed. Furthermore, in the present invention, the ink I does not have to be semi-cured in the ink ejection process.

  As described above, the embodiments and modifications of the present invention have been described, but the present invention is not limited to these. In the present invention, embodiments and modifications can be implemented in various other forms, and various omissions, replacements, changes in combinations, and the like can be made without departing from the spirit of the invention.

1 Inkjet printer (3D printer)
2a Work surface 41 Discharge part (enclosure wall installation part)
42 UV irradiator (exposure section)
5 Carriage drive unit (reciprocating unit)
61 Vertical direction moving part 62 Sub-scanning direction moving part 63 Axial center rotating part 7 Control part 9 Pressure contact part 9a Flat surface 10 Film delivery part E Enclosure wall F Film I Ink W 3D object LY layer

Claims (5)

An ejection unit that ejects ink whose degree of cure is changed by applying an external stimulus to the work surface;
And a reciprocating unit that reciprocates the ejecting unit in a main scanning direction, and a method for producing a three-dimensional structure to be executed in a three-dimensional printer that applies an external stimulus to the ink ejected to the work surface. And
An enclosure formed to have the same thickness as the layers constituting the three-dimensional structure by the reciprocating unit moving the ejection unit in the main scanning direction while the ejection unit ejects ink and gives an external stimulus. An enclosure wall installation process for installing the wall on the work surface;
After the enclosure wall installation step, the reciprocating unit moves the ejection unit in the main scanning direction, while the ejection unit is located inside the inner wall of the enclosure wall and the shape data for each layer of the three-dimensional structure An ink ejection process for ejecting ink based on
After the ink ejection step, a flat surface parallel to the work surface is pressed against the enclosure wall and the ink spaced inward from the inner surface of the enclosure wall, and the ink is completely cured by applying an external stimulus. Pressure welding curing process,
The manufacturing method of the three-dimensional structure characterized by including.   In the press-curing step, a film having flexibility is interposed between the press-contact portion and the work surface, and the film is pressed against the enclosure wall and the ink separated from the inner surface of the enclosure wall. The manufacturing method of the three-dimensional structure according to claim 1.   The method for manufacturing a three-dimensional structure according to claim 1 or 2, wherein the enclosure wall installation step, the ink discharge step, and the pressure-contact curing step are repeated a plurality of times.   In the ink ejection step, the external stimulus that is weaker than the external stimulus that is completely cured is applied to the ink that is spaced inward from the inner surface of the enclosure wall, or the external stimulus that is shorter than the time that the ink is completely cured The method for producing a three-dimensional structure according to any one of claims 1 to 3, wherein:   In the ink ejection step, the reciprocating unit moves the ejecting unit in the main scanning direction a plurality of times while the ejecting unit ejects ink, and the reciprocating unit moves the ejecting unit in the main scanning direction. 5. The method for producing a three-dimensional structure according to claim 4, wherein the external stimulus is applied to the ink that is spaced inward from the inner surface of the enclosure wall each time the inner wall is made to move.

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