JP2018094876A - Three-dimensional modeling apparatus and three-dimensional modeling method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a technique for improving molding accuracy in a three-dimensional modeling apparatus including an ejection head having a plurality of nozzles.SOLUTION: The present invention relates to a three-dimensional modeling apparatus comprising: a modeling stage S on which a material layer made of a molding material is formed; a lamination unit 20 for forming a material layer by ejecting a liquid molding material on the modeling stage S; a curing unit 40 for performing curing treatment on the material layer; and a moving mechanism 60 for relatively moving the modeling stage S, the lamination unit 20 and the curing unit 40. The lamination unit 20 has ejection heads 21, 22 for ejecting a molding material from a plurality of nozzles with respect to the modeling stage S. The ejection head ejects a molding material in a three-dimensional object formation range on the modeling stage S for each layer to form a material layer constituting the three-dimensional object, molding materials are ejected from all the nozzles in a preliminary ejection range different from the three-dimensional object formation range, ejection failures such as nozzle clogging of unused nozzles are suppressed, and therefore the three-dimensional modeling apparatus is capable of suppressing deterioration of forming accuracy of a three-dimensional object due to ejection failure.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a three-dimensional modeling apparatus and a three-dimensional modeling method for stacking modeling materials to form a three-dimensional object.

  In recent years, three-dimensional modeling techniques such as 3D printing are rapidly spreading. Modeled objects obtained by three-dimensional modeling are used for, for example, prototypes of industrial products, exhibits, and medical models. As a three-dimensional modeling method, an inkjet method, an optical modeling method, a powder method, and the like are known.

  In general, an inkjet three-dimensional modeling apparatus forms a material layer by discharging a modeling material from an ejection head, and stacks the material layer to manufacture a specified three-dimensional modeled object. Specifically, the material layer is formed by discharging an ultraviolet curable modeling material on the modeling stage. Then, the material layer is cured by irradiating the material layer with ultraviolet rays. By repeating such a molding material discharge process and an ultraviolet irradiation process by the irradiation unit, a modeled object is formed on the modeling stage. The ink jet three-dimensional modeling technique is described in, for example, Patent Document 1.

  The three-dimensional modeling apparatus described in Patent Literature 1 is a model material discharge head that discharges a model material that is finally obtained as a final modeled object, and a support that discharges a support material that forms a support unit that supports the final modeled object A material discharge head and a UV lamp that irradiates and cures the liquid model material or the liquid support material with ultraviolet light.

Japanese Patent Laying-Open No. 2015-150840

  In the three-dimensional modeling apparatus described in Patent Document 1, the model material discharge head and the support material discharge head discharge a modeling material such as a model material and a support material from a plurality of nozzles. In such a three-dimensional modeling apparatus, there is a nozzle that is not used for a long time depending on the shape of a model to be formed. If there is no discharge from the nozzle for a long time, there is a risk that the liquid modeling material dries in the nozzle, resulting in a discharge failure or the density of the discharged modeling material being increased. And thereby, there exists a possibility that the shaping | molding precision of a final molded article may fall.

  This invention is made | formed in view of such a situation, and it aims at providing the technique which improves a shaping | molding precision in a three-dimensional modeling apparatus provided with the discharge head which has a some nozzle.

  In order to solve the above-mentioned problem, the first invention of the present application is a three-dimensional modeling apparatus that forms modeling objects by stacking modeling materials, a modeling stage on which a material layer made of modeling materials is formed, and the modeling stage A stacking unit that discharges the liquid modeling material to form the material layer, a curing unit that performs a curing process on the material layer on the modeling stage, the modeling stage, the stacking unit, and the curing unit And a moving mechanism that relatively moves in the transport direction. The stacking unit includes one or more ejection heads that eject the modeling material from a plurality of nozzles arranged in the width direction with respect to the modeling stage that moves relatively in the conveyance direction. Each of the discharge heads discharges the modeling material to a three-dimensional object formation range that is a predetermined conveyance direction range on the modeling stage, and forms the material layer that constitutes the three-dimensional object. The modeling material is discharged from all the nozzles of the discharge head in a preliminary discharge range that is a conveyance direction range on the modeling stage different from the three-dimensional object formation range.

  2nd invention of this application is a three-dimensional modeling apparatus of Claim 1 of 1st invention, Comprising: The said discharge head is the said 3D object formation range in the said three-dimensional object formation range, respectively at the time of discharge of each layer of the said material layer. Before the discharge, the modeling material is discharged in the preliminary discharge range.

  A third invention of the present application is the three-dimensional modeling apparatus of the first invention or the second invention, and includes a plurality of the ejection heads. The plurality of ejection heads include a model material ejection head that ejects a liquid model material from the plurality of nozzles, and a support material ejection head that ejects a liquid support material from the plurality of nozzles. The preliminary discharge range includes a model material preliminary discharge range and a support material preliminary discharge range. The model material discharge head discharges the model material from all the nozzles in the model material preliminary discharge range, and the support material discharge head discharges the support material from all the nozzles in the support material preliminary discharge range. Discharge.

  4th invention of this application is the three-dimensional modeling apparatus of 3rd invention, Comprising: The said model material preliminary discharge range and the said support material preliminary discharge range are arrange | positioned adjacent to a conveyance direction.

  5th invention of this application is the three-dimensional modeling apparatus of 3rd invention, Comprising: The said model material preliminary discharge range is adjacent to the two said support material preliminary discharge ranges arrange | positioned at the both sides of a conveyance direction, and a conveyance direction. Arranged.

  A sixth invention of the present application is the three-dimensional modeling apparatus according to any one of the first to fifth inventions, wherein the modeling material is an energy curable material. The said hardening part irradiates an energy ray with respect to the said modeling material on the said modeling stage.

  7th invention of this application is a three-dimensional modeling apparatus of 6th invention, Comprising: The said modeling material is an ultraviolet curable material. The said hardening part irradiates an ultraviolet-ray with respect to the said modeling material on the said modeling stage.

  An eighth invention of the present application is the three-dimensional modeling apparatus according to any one of the first to seventh inventions, further comprising a roller for flattening the material layer before curing formed on the modeling stage.

  A ninth invention of the present application is a three-dimensional modeling method for forming a three-dimensional object on a modeling stage by a three-dimensional modeling apparatus having a laminated portion and a curing portion. The stacking unit includes a discharge head that discharges a liquid modeling material from a plurality of nozzles arranged in the width direction with respect to the modeling stage that moves relatively in the conveyance direction. In this three-dimensional modeling method, A) the stacking unit discharges the liquid modeling material from the discharge head toward the modeling stage, and B) the curing unit is liquid on the modeling stage. And the step of curing the modeling material. The step A) includes p) a step of discharging the modeling material from all the nozzles of the discharge head into a preliminary discharge range that is a predetermined conveyance direction range on the modeling stage, and q) the preliminary discharge range; Includes a step of discharging the modeling material from the discharge head to a three-dimensional object forming region which is a predetermined conveyance direction range on the different modeling stage to form a material layer constituting the three-dimensional object.

  A tenth invention of the present application is the three-dimensional modeling method of the ninth invention, wherein in the step A), the step q) is performed after the step p).

  An eleventh invention of the present application is the three-dimensional modeling method of the ninth invention or the tenth invention, wherein the discharge head discharges a liquid model material from a plurality of the nozzles, and a plurality of the model material discharge heads And a support material discharge head for discharging a liquid support material from the nozzle. The step A) includes A1) a step of discharging the liquid model material from the model material discharge head toward the modeling stage, and A2) a liquid state of the liquid from the support material discharge head toward the modeling stage. At least one of a step of discharging the support material. The step A1) includes a step of p1) discharging the model material from all the nozzles of the model material discharge head into the model material preliminary discharge range which is the preliminary discharge range; and q1) in the three-dimensional object formation region. And ejecting the model material from the model material ejection head to form the material layer constituting the three-dimensional object. In step A2), p2) the support material is discharged from all the nozzles of the support material discharge head into the support material preliminary discharge range which is the preliminary discharge range and is different from the model material preliminary discharge range. A step of discharging, and q2) discharging the support material from the support material discharge head to the three-dimensional object forming region to form the material layer constituting the three-dimensional object.

  A twelfth invention of the present application is the three-dimensional modeling method of the eleventh invention, wherein the model material preliminary discharge range and the support material preliminary discharge range are arranged adjacent to each other in the transport direction.

  A thirteenth invention of the present application is the three-dimensional modeling method according to the eleventh invention, wherein the model material preliminary discharge range is adjacent to the two support material preliminary discharge ranges arranged on both sides in the transport direction. Arranged.

  According to the first to thirteenth inventions of the present application, the modeling material is periodically discharged from all the nozzles by discharging from all the nozzles for each layer. As a result, ejection defects such as nozzle clogging in unused nozzles are suppressed. Therefore, it can suppress that the shaping | molding precision of a three-dimensional object falls due to discharge failure.

  According to the 2nd invention and the 10th invention of this application, before discharging a modeling material to a part which forms a solid thing part for every layer, discharging a modeling material from all the nozzles. Thereby, the discharge defect in a three-dimensional object part can be suppressed more. Therefore, it can suppress more that the shaping | molding precision of a solid thing falls.

  According to the fourth invention and the twelfth invention of the present application, the modeled object molded in the preliminary discharge range has a surface in contact with the support material, similarly to the target modeled object. Thereby, when using the modeled object shape | molded in the preliminary | backup discharge range as a sample, since the surface state becomes the same as the target modeled object, it is useful. Further, when the model material is a soft material, there is a possibility that the model material will fall if it is piled up high in a narrow area. For this reason, it is suppressed that a model material falls down during a modeling process by putting a support material along with adjacent.

  According to the fifth and thirteenth inventions of the present application, in the case where the model material is a soft material, the support of the support material on both sides in the transport direction further suppresses the model material from falling during the modeling process.

It is the figure which showed the structure of the three-dimensional modeling apparatus which concerns on 1st Embodiment. It is the figure which showed the structure of the lamination apparatus which concerns on 1st Embodiment. It is a front view of the modeling stage of the lamination apparatus concerning a 1st embodiment, a shielding board, a raising / lowering mechanism, and a movement mechanism. It is a side view of the modeling stage of the lamination apparatus concerning a 1st embodiment, a shielding board, a raising / lowering mechanism, and a movement mechanism. It is the block diagram which showed the connection of the control part of the lamination apparatus which concerns on 1st Embodiment, and each part in a lamination apparatus. It is the flowchart which showed the process of the three-dimensional modeling of the lamination apparatus which concerns on 1st Embodiment. It is an example of the solid thing formed with the lamination apparatus concerning a 1st embodiment. It is the flowchart which showed the process of the three-dimensional modeling of the lamination apparatus which concerns on 2nd Embodiment. It is an example of the three-dimensional object formed with the lamination apparatus which concerns on 2nd Embodiment. It is the figure which showed the structure of the lamination | stacking apparatus which concerns on 3rd Embodiment. It is the flowchart which showed the process of the three-dimensional modeling of the lamination | stacking apparatus which concerns on 3rd Embodiment. It is an example of the solid thing formed with the lamination | stacking apparatus which concerns on 3rd Embodiment. It is the flowchart which showed the flow of the model material discharge process of the lamination | stacking apparatus which concerns on 3rd Embodiment. It is the flowchart which showed the flow of the support material discharge process of the lamination apparatus which concerns on 3rd Embodiment. It is the flowchart which showed the flow of the support material discharge process of the lamination apparatus which concerns on 3rd Embodiment. It is the flowchart which showed the flow of the model material discharge process of the lamination | stacking apparatus which concerns on 3rd Embodiment.

  Embodiments of the present invention will be described below with reference to the drawings.

<1. First Embodiment>
<1-1. Configuration of 3D modeling equipment>
FIG. 1 is a diagram illustrating a configuration of a three-dimensional modeling apparatus 1 according to the first embodiment. The three-dimensional modeling apparatus 1 includes a carry-in device 11, a stacking device 10, a transport device 12, a cleaning device 13, and a carry-out device 14.

  The carry-in device 11 is a device that conveys a modeling stage S to be described later to the stacking device 10. The carry-in device 11 has a first transport mechanism 110. The first transport mechanism 110 is configured by, for example, a robot mechanism, a roller mechanism, or the like. However, the first transport mechanism 110 may be configured by other mechanisms. When the modeling stage S is carried into the carry-in device 11 from the outside, the modeling stage S is conveyed to the stacking device 10 by the first conveyance mechanism 110. The configuration of the stacking apparatus 10 will be described later.

  The transport device 12 is a device that transports the modeling stage S from the stacking device 10 to the cleaning device 13. The transport device 12 includes a second transport mechanism 120. The second transport mechanism 120 is configured by, for example, a robot mechanism, a roller mechanism, or the like. However, the second transport mechanism 120 may be configured by another mechanism. When the three-dimensional object 9 formed by laminating the model material and the support material is formed on the upper surface of the modeling stage S by the stacking device 10, the modeling stage S is transported to the cleaning device 13 by the second transport mechanism 120.

  The cleaning device 13 is a device that removes the support material from the three-dimensional object 9. The cleaning device 13 includes a treatment tank 131 filled with a chemical solution 132. When the modeling stage S is carried into the cleaning device 13, the three-dimensional object 9 is immersed in the chemical solution 132 of the processing tank 131. Thereby, the support material is removed from the three-dimensional object 9. As a result, the final modeled object 900 made of the model material remains on the upper surface of the modeling stage S.

  The carry-out device 14 is a device that carries out the modeling stage S from the cleaning device 13 to the outside of the three-dimensional modeling device 1. The carry-out device 14 has a third transport mechanism 140. The third transport mechanism 140 is constituted by, for example, a robot mechanism or a roller mechanism. However, the third transport mechanism 140 may be configured by another mechanism. After the support material is removed from the three-dimensional object 9 in the cleaning device 13, the modeling stage S is carried out of the device by the third transport mechanism 140 of the carry-out device 14.

<1-2. Configuration of laminating apparatus>
Next, the configuration of the stacking apparatus 10 will be described. FIG. 2 is a diagram illustrating a configuration of the stacking apparatus 10 according to the present embodiment. Here, the positional relationship of each part of the modeling stage that reciprocates along the conveying direction extending in the horizontal direction will be described with the forward direction being the front and the backward direction being the rear. A direction orthogonal to the transport direction and extending in the horizontal direction is referred to as a width direction. However, there is no intention to limit the orientation of the laminating apparatus 10 and the three-dimensional modeling apparatus 1 by the definition of the front-rear direction.

  The laminating apparatus 10 is an apparatus that forms a three-dimensional object 9 made of a model material and a support material that are modeling materials in the manufacturing process of the final modeled object 900 in three-dimensional modeling. The model material and the support material of the present embodiment are both ultraviolet curable materials. The model material is a modeling material that constitutes the target final model 900. The support material is a support material that supports the modeling material in order to prevent the modeling material from being collapsed or bent during the manufacturing of the modeled object. The three-dimensional object 9 is formed by laminating a material layer made of a model material and a support material.

  As illustrated in FIG. 2, the stacking apparatus 10 according to the present embodiment includes a stacking unit 20, a roller unit 30, an irradiation unit 40, an elevating mechanism 50, a moving mechanism 60, and a control unit 100.

  The stacking unit 20 stacks a material layer 90 made of a model material and a support material on the modeling stage S carried in from the carry-in device 11 to form the material layer 90. The modeling stage S is a support base that supports the material layer 90. The modeling stage S has an upper surface that extends horizontally. As shown by the arrows and broken line arrows in FIG. 2, the modeling stage S moves in the front-rear direction and downward by the elevating mechanism 50 and the moving mechanism 60. And while the modeling stage S moves, the material layer 90 which consists of a model material and a support material is laminated | stacked in order on the upper surface. Thereby, the three-dimensional object 9 is formed on the upper surface of the modeling stage S. In addition, in order to suppress the reflection of the ultraviolet rays described later, the surface of the modeling stage S may be subjected to an antireflection treatment such as a black coating treatment or a black film sticking.

  The stacking unit 20 forms a material layer 90 on the upper surface of the modeling stage S by discharging a liquid modeling material (model material and support material) onto the modeling stage S. The stacked unit 20 includes a first discharge head 21 and a second discharge head 22 disposed in front of the first discharge head 21. The first discharge head 21 and the second discharge head 22 are each arranged above the transport path of the modeling stage S. The first ejection head 21 selectively ejects droplets of a model material from a plurality of nozzles arranged in the width direction with respect to the modeling stage S that moves relatively in the front-rear direction that is the transport direction. Head. The second ejection head 22 selectively ejects support material droplets from a plurality of nozzles arranged in the width direction with respect to the modeling stage S that moves relatively in the front-rear direction, which is the transport direction. Head.

  The roller unit 30 includes a first roller 31 and a second roller 32. Each of the first roller 31 and the second roller 32 is a rotating body having a cylindrical outer peripheral surface. As the material of the rollers 31 and 32, for example, a metal such as SUS having higher hardness than the model material and the support material constituting the material layer 90 is used. The first roller 31 is disposed in front of the first ejection head 21 and behind the irradiation unit 40. The second roller 32 is disposed behind the second ejection head 22 and in front of the irradiation unit 40.

  Each of the rollers 31 and 32 is supported so as to be rotatable about a horizontally extending rotation axis. The rollers 31 and 32 are connected to a drive source such as a motor (not shown), for example. When the motor is driven, the rollers 31 and 32 rotate around the rotation shaft together with the output shaft of the motor. The roller unit 30 flattens the upper surface of the liquid material layer 90 before curing after either of the discharge heads 21 and 22 discharges the liquid modeling material to the uppermost layer of the material layer 90. When performing the flattening process, the modeling stage S is moved in the front-rear direction, and the rollers 31 and 32 are rotated while the rollers 31 and 32 are in contact with the upper surface of the material layer 90. Thereby, the upper surface of the material layer 90 is planarized. The first roller 31 flattens the upper surface of the liquid model material discharged by the first discharge head 21. The second roller 32 flattens the upper surface of the liquid support material discharged by the second discharge head 22.

  The irradiation unit 40 is a curing unit that performs a curing process on the material layer 90 on the modeling stage S. Specifically, the irradiation unit 40 irradiates the material layer 90 formed on the upper surface of the modeling stage S with ultraviolet rays. The irradiation unit 40 is disposed between the first ejection head 21 and the first roller 31, and the second ejection head 22 and the second roller 32. Further, the irradiation unit 40 is disposed above the conveyance path of the modeling stage S.

  The irradiation unit 40 has its irradiation timing and light emission intensity controlled by the control unit 100 described later. As a light source of the irradiation unit 40, for example, a UV lamp is used. However, a metal halide lamp, a xenon lamp, an LED lamp, or the like may be used as the light source of the irradiation unit 40.

  The lifting mechanism 50 is a mechanism that moves the modeling stage S up and down. FIG. 3 is a front view of the modeling stage S, the elevating mechanism 50, and the moving mechanism 60. FIG. 4 is a side view of the modeling stage S, the lifting mechanism 50, and the moving mechanism 60. The lifting mechanism 50 of the present embodiment uses a mechanism that converts the rotational motion of the motor into a straight motion via a ball screw. The modeling stage S is supported on the holding unit 51. The holding portion 51 is attached to the ball screw so as to mesh with a spiral screw groove provided on the outer peripheral surface of the ball screw. When a motor (not shown) is driven, the ball screw rotates about its axis. Thereby, the holding | maintenance part 51 and the modeling stage S move to an up-down direction along a ball screw. However, another mechanism such as a linear motor may be used for the lifting mechanism 50.

  The moving mechanism 60 is a mechanism that reciprocates the modeling stage S in the front-rear direction. Thereby, the moving mechanism 60 moves the modeling stage S, the lamination | stacking part 20, the roller part 30, and the irradiation part 40 relatively in a conveyance direction. A linear motor mechanism is used for the moving mechanism 60 of the present embodiment. The moving mechanism 60 includes a guide 61, a drive unit 62, and a connection unit 63. The connection unit 63 connects the drive unit 62 and the casing of the lifting mechanism 50. When the linear motor is driven, the drive unit 62 moves back and forth along the guide 61. Thereby, the elevating mechanism 50 and the modeling stage S connected to the drive unit 62 move in the front-rear direction along the guide 61 as a unit. However, other mechanisms such as a ball screw may be used for the moving mechanism 60.

  The control unit 100 is means for controlling the operation of each unit in the stacking apparatus 10. FIG. 5 is a block diagram showing connections between the control unit 100 and each unit in the stacking apparatus 10. As conceptually shown in FIG. 5, the control unit 100 is configured by a computer having an arithmetic processing unit 101 such as a CPU, a memory 102 such as a RAM, and a storage unit 103 such as a hard disk drive. A computer program P for executing each process by the stacking apparatus 10 is installed in the storage unit 103.

  As shown in FIG. 5, the control unit 100 includes a first discharge head 21 and a second discharge head 22 of the stacking unit 20, a first roller 31 and a second roller 32 of the roller unit 30, an irradiation unit 40, and an elevation unit. The mechanism 50 and the moving mechanism 60 are connected to be able to communicate with each other. The control unit 100 temporarily reads the computer program P and data stored in the storage unit 103 into the memory 102, and the arithmetic processing unit 101 performs arithmetic processing based on the computer program P, whereby each of the above units is performed. Control the operation. Thereby, the conveyance process of the modeling stage S, the discharge process of the model material and the support material, the ultraviolet irradiation process, and the flattening process proceed.

<1-3. Lamination process>
Next, the laminating process by the above laminating apparatus 10 will be described with reference to FIGS. 6 and 7. FIG. 6 is a flowchart showing the process of the stacking process of the present embodiment. FIG. 7 is a cross-sectional view showing an example of the three-dimensional object 9 obtained by the lamination process of the present embodiment.

  When performing the lamination process, design data obtained by dividing the shape of a three-dimensional object to be manufactured for each height position is input to the control unit 100 in advance. And the control part 100 performs the lamination process mentioned later according to the said design data. As a result, a three-dimensional object 9 is obtained on the modeling stage S as shown in FIG.

  Here, as shown in FIG. 7, on the upper surface of the modeling stage S, a three-dimensional object formation range A1, which is a predetermined conveyance direction range on the modeling stage S, a first preliminary discharge range A2, and a second preliminary discharge range. And A3. In the three-dimensional object formation range A1, a main modeled object 91 described later is formed. In the present embodiment, the first preliminary discharge range A2 is disposed in front of the three-dimensional object formation range A1. The second preliminary discharge range A3 is arranged behind the three-dimensional object formation range A1.

  In the stacking process of the present embodiment, as the three-dimensional object 9, a main model 91 including the final model 900, and a first sub-model 921 and a second sub-model 922 formed by the preliminary discharge process are formed. . The main model 91 is formed on the three-dimensional object formation range A1 of the modeling stage S. Further, the first sub-modeling object 921 is formed on the first preliminary discharge range A2 of the modeling stage S. The second sub-modeled object 922 is formed on the second preliminary discharge range A3 of the modeling stage S.

  In the lamination process, first, the modeling stage S is arranged at the rear end which is the initial position (step S11). In the present embodiment, the rear end is behind the first ejection head 21 and the first roller 31 as shown in FIG. In step S11, the upper surface of the modeling stage S and the lower ends of the first roller 31 and the second roller 32 are arranged at the rear end with a distance of one material layer in the vertical direction. In the lamination process of the present embodiment, the modeling material S is stacked and cured for one layer while the modeling stage S is conveyed in the front-rear direction by the moving mechanism 60. Then, the elevating mechanism 50 lowers the modeling stage S by the thickness of the modeled layer. The stacking process proceeds by repeating the stacking / curing of the modeling material and the lowering of the modeling stage S.

  When the modeling stage S is arranged at the rear end in step S11, the moving mechanism 60 subsequently moves the modeling stage S from the rear end toward the front. Thereby, the modeling stage S passes below the first discharge head 21. The first discharge head 21 discharges the droplet of the model material toward the upper surface of the modeling stage S passing below, based on the divided data (step S12).

  Step S12 includes a model material preliminary discharge step (step S121) and a model material main discharge step (step S122).

  In step S12, first, the first discharge head 21 discharges droplets of the model material from all nozzles in the first preliminary discharge range A2 (step S121). Thereby, one layer of the model material is formed in all the regions in the width direction of the first preliminary discharge range A2. The model material layer forms the first sub-modeling object 921. As described above, the first preliminary discharge range A2 is a model material preliminary discharge range in which preliminary discharge of the model material is performed.

  Here, in the present embodiment, “all nozzles” means all nozzles arranged in the width direction range in which the main structure 91 is formed in the three-dimensional object formation range A1. Further, “all regions in the width direction” means all regions in the width direction range in which the main object 91 is formed in the three-dimensional object formation range A1. For this reason, it is not necessary to perform preliminary discharge of the model material in step S121 for the nozzles arranged in the width direction range where the formation of the main model 91 is not performed.

  In the preliminary discharge process of the model material, “all nozzles” that are discharged include all of the nozzles from which the model material is discharged when forming the main structure 91 formed in the three-dimensional object formation range A1. If it is, it is not necessary to include all the nozzles arranged in the width direction range in which the main model 91 is formed in the three-dimensional object formation range A1.

  Thereafter, the first discharge head 21 discharges the droplet of the model material based on the divided data in the three-dimensional object formation range A1 (step S122). As a result, one layer of model material corresponding to the shape of each height position of the design data is formed. The layer of the model material forms a material layer 90 constituting the main modeled object 91. Further, the layer of the model material forms a part of the main model 91 that becomes the final model 900.

  Next, the moving mechanism 60 moves the modeling stage S further forward. Thereby, the upper surface of the liquid model material layer formed in step S <b> 12 and the outer peripheral surface of the first roller 31 come into contact with each other. As a result, the upper surface of the model material layer is flattened by the first roller 31 (step S13). At this time, as indicated by an arrow in FIG. 2, the first roller 31 rotates in a direction against the forward movement of the modeling stage S. Thereby, the model material layer can be efficiently planarized.

  When the layer of the model material is flattened, subsequently, the moving mechanism 60 moves the modeling stage S further forward and passes under the irradiation unit 40. The irradiation unit 40 irradiates ultraviolet rays toward the modeling stage S passing below (step S14). Thereby, the layer of the model material formed on the upper surface of the modeling stage S is cured.

  Subsequently, the moving mechanism 60 moves the modeling stage S further forward. Then, the modeling stage S passes below the second roller 32. At this time, the cured model material layer comes into contact with the second roller 32. Subsequently, the moving mechanism 60 moves the modeling stage S forward. Thereby, the modeling stage S passes below the second ejection head 22. Then, the moving mechanism 60 further moves the modeling stage S forward, and the modeling stage S is arranged at the front end.

  Next, the moving mechanism 60 moves the modeling stage S from the front end toward the rear. As a result, the modeling stage S passes below the second ejection head 22. Based on the divided data, the second ejection head 22 ejects droplets of the support material toward the upper surface of the modeling stage S that passes below (step S15).

  Step S15 includes a support material preliminary discharge step (step S151) and a support material main discharge step (step S152).

  In step S15, first, the second discharge head 22 discharges droplets of the support material from all the nozzles in the second preliminary discharge range A3 (step S151). Thereby, one layer of the support material is formed in all the regions in the width direction of the second preliminary discharge range A3. The layer of the support material forms the second sub-modeling object 922. As described above, the second preliminary discharge range A3 is a support material preliminary discharge range in which preliminary discharge of the support material is performed.

  Here, in the present embodiment, “all nozzles” means all nozzles arranged in the width direction range in which the main structure 91 is formed in the three-dimensional object formation range A1. Further, “all regions in the width direction” means all regions in the width direction in which the three-dimensional object 9 is formed in the three-dimensional object formation range A1. For this reason, about the nozzle arrange | positioned in the width direction range in which formation of the main molded article 91 is not performed, it is not necessary to perform preliminary discharge of the support material in step S151.

  In the support material preliminary discharge step, “all nozzles” that are discharged include all of the nozzles from which the support material is discharged when forming the main structure 91 formed in the three-dimensional object formation range A1. If it is, it is not necessary to include all the nozzles arranged in the width direction range in which the main model 91 is formed in the three-dimensional object formation range A1.

  Thereafter, the second ejection head 22 ejects droplets of the support material in the three-dimensional object formation range A1 based on the divided data (step S152). Thereby, one layer of support material corresponding to the shape of each height position of the design data is formed. The layer of the support material forms a material layer 90 constituting the main modeled object 91.

  Subsequently, the moving mechanism 60 moves the modeling stage S further rearward. As a result, the upper surface of the liquid support material layer formed in step S <b> 15 and the outer peripheral surface of the second roller 32 come into contact with each other. As a result, the upper surface of the support material layer is flattened by the second roller 32 (step S16). At this time, as indicated by an arrow in FIG. 2, the second roller 32 rotates in a direction against the backward movement of the modeling stage S. Thereby, the layer of support material can be planarized efficiently.

  When the support material layer is flattened, subsequently, the moving mechanism 60 moves the modeling stage S further rearward and passes under the irradiation unit 40. The irradiation unit 40 irradiates ultraviolet rays toward the modeling stage S that passes below (step S17). Thereby, the layer of the support material formed on the upper surface of the modeling stage S is cured.

  Thereafter, the moving mechanism 60 moves the modeling stage S further rearward. And after passing under the 1st roller 31 and the 1st discharge head 21, modeling stage S is arranged to the back end. At the rear end, the lifting mechanism 50 lowers the modeling stage S by the height of the material layer 90 for one layer. The lifting mechanism 50 may lower the modeling stage S below the irradiation unit 40 before moving to the rear end after step S17.

  Subsequently, the control unit 100 checks whether or not there is a next material layer to be stacked (step S19). And when there exists the next material layer which should be laminated | stacked, it returns to step S12 and repeats the process of step S12-S18, and further laminates | stacks a material layer. On the other hand, when the lamination of all the material layers is completed, the lamination process is finished.

  Thus, in this laminating apparatus 10, each ejection head 21, 22 causes droplets of modeling material from all the nozzles used in the preliminary ejection ranges A2, A3 different from the three-dimensional object formation range A1 for each layer. Discharge. Thereby, in each discharge head 21 and 22, preliminary discharge of a modeling material is made periodically from all the nozzles used. Therefore, discharge defects such as nozzle clogging are suppressed. As a result, it can suppress that the shaping | molding precision of the main molded article 91 falls due to discharge failure. That is, the molding accuracy of the final model 900 can be improved.

  In particular, in the present embodiment, the first discharge head 21 performs the model material in the first preliminary discharge range A2 in step S121 before the main discharge of the model material in the three-dimensional object formation range A1 in step S122 for each layer. The preliminary discharge is performed. Further, the second discharge head 22 performs preliminary discharge of the support material in the second preliminary discharge range A3 in step S151 before the main discharge of the support material in the three-dimensional object formation range A1 in step S152 for each layer. . Thus, preliminary discharge is performed immediately before the main discharge of each modeling material. As described above, in each of the ejection heads 21 and 22, by performing preliminary ejection immediately before the main ejection for forming the main shaped article 91, ejection failure in the main ejection can be further suppressed. Therefore, the molding accuracy of the final model 900 can be further improved.

  In the laminating apparatus 10, both the model material and the support material are cured by the single irradiation unit 40 disposed between the first ejection head 21 and the second ejection head. Therefore, the number of expensive irradiation parts can be suppressed. As a result, the manufacturing cost of the laminating apparatus 10 and the three-dimensional modeling apparatus 1 can be reduced. Furthermore, the stacking apparatus 10 and the three-dimensional modeling apparatus 1 can be reduced in size.

<2. Second Embodiment>
Next, the lamination process according to the second embodiment will be described with reference to FIGS. 8 and 9. Since the laminating apparatus that performs the laminating process according to the second embodiment is the same as the laminating apparatus 10 according to the first embodiment, the description thereof is omitted. FIG. 8 is a flowchart showing the process of the stacking process of the second embodiment. FIG. 9 is a cross-sectional view showing an example of a three-dimensional object 9B obtained by the laminating process of the second embodiment liquid.

  As shown in FIG. 9, the upper surface of the modeling stage S includes a three-dimensional object formation range B1 that is a predetermined conveyance direction range on the modeling stage S, a first preliminary discharge range B2, a second preliminary discharge range B3, and a third preliminary stage. And a discharge range B4. In the three-dimensional object formation range B1, a main object 91B including the final object is formed. The first preliminary discharge range B2, the second preliminary discharge range B3, and the third preliminary discharge range B4 are arranged adjacent to each other in the transport direction in front of the three-dimensional object formation range B1.

  In the stacking process of the present embodiment, as the three-dimensional object 9B, the main modeled object 91B including the final modeled object and the sub-modeled object 92B formed by the preliminary discharge process are formed. The main modeled object 91B is formed on the three-dimensional object forming range B1 of the modeling stage S. The sub-modeling object 92B is formed over the first preliminary discharge range B2, the second preliminary discharge range B3, and the third preliminary discharge range B4 on the modeling stage S.

  In the lamination process, first, the modeling stage S is arranged at the rear end (step S21). Next, the moving mechanism 60 moves the modeling stage S from the rear end toward the front. When the modeling stage S passes below the first ejection head 21, the first ejection head 21 drops droplets of the model material toward the upper surface of the modeling stage S passing below. Discharge (step S22).

  Step S22 includes a model material preliminary discharge step (step S221) and a model material main discharge step (step S222).

  In step S22, first, the first discharge head 21 discharges droplets of the model material from all the nozzles in the second preliminary discharge range B3 (step S221). Thereby, one layer of the model material is formed in all the regions in the width direction of the second preliminary discharge range B3. As described above, the second preliminary discharge range B3 is a model material preliminary discharge range in which preliminary discharge of the model material is performed.

  Here, in the present embodiment, “all nozzles” means all nozzles arranged in the width direction range in which the main modeled object 91B is formed in the three-dimensional object forming range B1. Moreover, “all the areas in the width direction” means all the areas in the width direction range where the main object 91B is formed in the three-dimensional object formation range B1.

  Thereafter, the first discharge head 21 discharges the droplet of the model material based on the divided data in the three-dimensional object formation range B1 (step S222). As a result, one layer of model material corresponding to the shape of each height position of the design data is formed. The layer of the model material forms a part to be the final modeled object in the main modeled object 91B.

  Next, the moving mechanism 60 moves the modeling stage S further forward. As a result, the upper surface of the liquid model material layer formed in step S <b> 22 and the outer peripheral surface of the first roller 31 come into contact with each other. As a result, the upper surface of the model material layer is flattened by the first roller 31 (step S23).

  Subsequently, the moving mechanism 60 moves the modeling stage S further forward and passes below the irradiation unit 40. The irradiation unit 40 irradiates ultraviolet rays toward the modeling stage S that passes below (step S24). Thereby, the layer of the model material formed on the upper surface of the modeling stage S is cured.

  Thereafter, the moving mechanism 60 moves the modeling stage S further forward. The modeling stage S is disposed at the front end after passing below the second roller 32 and the second ejection head 22.

  Next, the moving mechanism 60 moves the modeling stage S from the front end toward the rear. As a result, the modeling stage S passes below the second ejection head 22. Based on the divided data, the second ejection head 22 ejects droplets of the support material toward the upper surface of the modeling stage S that passes below (step S25).

  Step S25 includes a support material main discharge step (step S251) and a support material preliminary discharge step (step S252).

  In step S25, first, the second ejection head 22 ejects droplets of the support material in the three-dimensional object formation range B1 based on the divided data (step S251). Thereby, one layer of support material corresponding to the shape of each height position of the design data is formed. The layer of the support material forms part of the main modeled object 91B.

  Thereafter, the second ejection head 22 ejects droplets of the support material from all the nozzles in the third preliminary ejection range B4 and the first preliminary ejection range B2 (step S252). Thereby, one layer of the support material is formed in all regions in the width direction of the first preliminary discharge range B2 and the third preliminary discharge range B4. As described above, the first preliminary discharge range B2 and the third preliminary discharge range B4 are support material preliminary discharge ranges in which preliminary discharge of the support material is performed. The support material layer and the model material layer formed in step S221 form the sub-modeling object 92B.

  Subsequently, the moving mechanism 60 moves the modeling stage S further rearward. As a result, the upper surface of the liquid support material layer formed in step S <b> 25 and the outer peripheral surface of the second roller 32 come into contact with each other. As a result, the upper surface of the support material layer is flattened by the second roller 32 (step S26).

  The moving mechanism 60 moves the modeling stage S further rearward and passes below the irradiation unit 40. The irradiation unit 40 irradiates ultraviolet rays toward the modeling stage S passing below (step S27). Thereby, the layer of the support material formed on the upper surface of the modeling stage S is cured.

  Thereafter, the moving mechanism 60 moves the modeling stage S further rearward. And after passing under the 1st roller 31 and the 1st discharge head 21, modeling stage S is arranged to the back end. At the rear end, the elevating mechanism 50 lowers the modeling stage S by the height of one material layer.

  Subsequently, the control unit 100 confirms whether or not there is a next material layer to be laminated (step S29). If there is a next material layer to be laminated, the process returns to step S22, and the process of steps S22 to S28 is repeated to further laminate the material layer. On the other hand, when the lamination of all the material layers is completed, the lamination process is finished.

  In the second embodiment, in the laminating apparatus 10, each ejection head 21, 22 has a modeling material from all the nozzles used in the preliminary ejection ranges B 2, B 3, B 4 different from the three-dimensional object formation range B 1 for each layer. Liquid droplets are discharged. Thereby, in each discharge head 21 and 22, preliminary discharge of a modeling material is made periodically from all the nozzles used. Therefore, discharge defects such as nozzle clogging are suppressed. As a result, it can suppress that the shaping | molding precision of the main molded article 91B falls due to discharge failure. That is, the molding accuracy of the final model can be improved.

  Since the sub-modeled object 92B is molded under the same conditions as the main modeled object 91B, it can be used as a sample for inspecting the properties and state of the main modeled object 91B and the final modeled object. In the present embodiment, when performing the step of removing the support material from the main modeled object 91B to obtain the final modeled object, the support material is also removed from the sub-modeled object 92B. And the model material contained in sub-modeling thing 92B is used as a sample.

  In the present embodiment, the second preliminary discharge range B3 that is the model material preliminary discharge range, and the first preliminary discharge range B2 and the third preliminary discharge range B4 that are the support material preliminary discharge ranges are arranged adjacent to each other in the transport direction. Is done. For this reason, the end surface of the transport direction of the model material modeled in the second preliminary discharge range B3 is in contact with the support material. The sample obtained from the sub-modeling object 92B of this embodiment has a surface formed in contact with the support material. The final model formed by the model material has different surface states when the outer surface is formed in contact with the support material and when it is formed without contact with the support material. For this reason, like this embodiment, when using the modeling thing shape | molded in a preliminary discharge range as a sample, it is preferable that there exists a surface which contacts a support material.

  In particular, in the present embodiment, the final modeled object that is the object of modeling is an organ model such as a heart. For this reason, a flexible material is used as a model material. When the model material is a flexible material, there is a risk of collapsing in the middle of the stacking process if the material is stacked in an elongated area such as the preliminary discharge range. As in the present embodiment, by stacking the support material in the first preliminary discharge range B2 or the third preliminary discharge range B4 adjacent to the second preliminary discharge range B3 in which the model material is stacked, the model material is obtained during the stacking process. The collapse is suppressed. In the present embodiment, the support material is laminated on both sides in the transport direction of the second preliminary discharge range B3, thereby further suppressing the collapse of the model material during the lamination process.

<3. Third Embodiment>
Next, a stacking process in the stacking apparatus 10C according to the third embodiment will be described with reference to FIGS. FIG. 10 is a diagram illustrating a configuration of the stacking apparatus 10C. FIG. 11 is a flowchart illustrating the process of the stacking process according to the third embodiment. FIG. 12 is a cross-sectional view showing an example of a three-dimensional object 9C obtained by the laminating process of the second embodiment liquid. FIG. 13 is a flowchart showing the flow of the model material discharge process in step S32. FIG. 14 is a flowchart showing the flow of the support material discharge process in step S34. FIG. 15 is a flowchart showing the flow of the support material discharge process in step S35. FIG. 16 is a flowchart showing the flow of the model material discharge process in step S38.

  As illustrated in FIG. 10, the stacking apparatus 10 </ b> C that performs the stacking process according to the third embodiment is different from the stacking apparatus 10 according to the first embodiment in the position of the first roller 31 </ b> C. In the stacking apparatus 10C of the present embodiment, the first roller 31C is disposed behind the first ejection head 21C. The other configuration of the laminating apparatus 10C is almost the same as that of the laminating apparatus 10 according to the first embodiment.

  As shown in FIG. 12, the upper surface of the modeling stage S includes a three-dimensional object formation range C1 that is a predetermined conveyance direction range on the modeling stage S, a first preliminary discharge range C2, a second preliminary discharge range C3, and a third preliminary discharge. It includes a discharge range C4, a fourth preliminary discharge range C5, a fifth preliminary discharge range C6, and a sixth preliminary discharge range C7. In the three-dimensional object formation range C1, the main modeled object 91C including the final modeled object is formed. The first preliminary discharge range C2, the second preliminary discharge range C3, and the third preliminary discharge range C4 are arranged adjacent to each other in the transport direction in front of the three-dimensional object formation range C1. The fourth preliminary discharge range C5, the fifth preliminary discharge range C6, and the sixth preliminary discharge range C7 are arranged adjacent to each other in the transport direction behind the three-dimensional object formation range C1.

  In the lamination process of the present embodiment, as the three-dimensional object 9C, the main modeled object 91C including the final modeled object, and the first sub-modeled object 921C and the second sub-modeled object 922C formed by the preliminary discharge process are formed. The main model 91C is formed on the three-dimensional object formation range C1 of the modeling stage S. Further, the first sub-modeled object 921C is formed over the first preliminary discharge range C2, the second preliminary discharge range C3, and the third preliminary discharge range C4 on the modeling stage S. The second sub-modeled object 922C is formed over the fourth preliminary discharge range C5, the fifth preliminary discharge range C6, and the sixth preliminary discharge range C7 on the modeling stage S.

  In the lamination process, first, the modeling stage S is arranged at the rear end which is the initial position (step S31). In step S31, at the rear end, the upper surface of the modeling stage S and the lower ends of the first roller 31C and the second roller 32C are arranged with a distance of two material layers in the vertical direction. In the lamination process of the present embodiment, the modeling material S is laminated and cured by two layers while the modeling stage S is conveyed in the front-rear direction by the moving mechanism 60C. Then, the modeling stage S is lowered by the thickness of the layer formed by the lifting mechanism 50C. The stacking process proceeds by repeating the stacking / curing of the modeling material and the lowering of the modeling stage S.

  When the modeling stage S is arranged at the rear end in step S31, the moving mechanism 60C subsequently moves the modeling stage S from the rear end toward the front. As a result, the modeling stage S passes below the first roller 31C. Subsequently, the modeling stage S passes below the first ejection head 21C. 21 C of 1st discharge heads discharge the droplet of a model material toward the upper surface of the modeling stage S which passes below based on the divided | segmented data (step S32).

  As shown in FIG. 13, step S32 includes a model material preliminary discharge step (step S321), a model material main discharge step (step S322), and a model material preliminary discharge step (step S323).

  In step S32, first, the first discharge head 21C discharges droplets of the model material from all the nozzles in the second preliminary discharge range C3 (step S321). Thereby, one layer of the model material is formed in all regions in the width direction of the second preliminary discharge range C3. The model material layer forms a part of the first sub-modeling object 921C. As described above, the second preliminary discharge range C3 is a model material preliminary discharge range in which preliminary discharge of the model material is performed.

  Next, the first ejection head 21C ejects a droplet of a model material based on the divided data in the three-dimensional object formation range C1 (step S322). As a result, one layer of model material corresponding to the shape of each height position of the design data is formed. The layer of the model material forms a portion to be the final modeled object in the main modeled object 91C.

  Subsequently, the first ejection head 21C ejects the droplets of the model material from all the nozzles in the fifth preliminary ejection range C6 (Step S323). Thereby, one layer of the model material is formed in all regions in the width direction of the fifth preliminary discharge range C6. The model material layer forms part of the second sub-model 922C. As described above, the fifth preliminary discharge range C6 is a model material preliminary discharge range in which the preliminary discharge of the model material is performed.

  When step S32 ends, the moving mechanism 60C moves the modeling stage S further forward and passes below the irradiation unit 40C. The irradiation unit 40C irradiates ultraviolet rays toward the modeling stage S that passes below (step S33). Thereby, the layer of the model material formed on the upper surface of the modeling stage S in step S32 (after the second time, step S38 and step S32) is cured.

  Then, the moving mechanism 60C moves the modeling stage S further forward. Then, the modeling stage S passes below the second roller 32C. At this time, the cured model material layer does not contact the second roller 32C. Subsequently, the moving mechanism 60C moves the modeling stage S forward. Thereby, the modeling stage S passes below the second ejection head 22. The second ejection head 22C ejects droplets of the support material based on the divided data toward the upper surface of the modeling stage S that passes below (step S34).

  As shown in FIG. 14, step S34 includes a support material preliminary discharge step (step S341), a support material main discharge step (step S342), and a support material preliminary discharge step (step S343).

  In step S341, first, the second ejection head 22C ejects support material droplets from all nozzles in the first preliminary ejection range C2 and the third preliminary ejection range C4 (step S341). Thereby, one layer of the support material is formed in all regions in the width direction of the first preliminary discharge range C2 and the third preliminary discharge range C4. The layer of the support material forms a part of the first sub-model 921C. As described above, the first preliminary discharge range C2 and the third preliminary discharge range C4 are support material preliminary discharge ranges in which preliminary discharge of the support material is performed.

  Next, the second ejection head 22C ejects droplets of the support material based on the divided data in the three-dimensional object formation range C1 (step S342). Thereby, one layer of support material corresponding to the shape of each height position of the design data is formed. The layer of the support material forms a part of the main modeled object 91C.

  Subsequently, the second discharge head 22C discharges droplets of the support material from all the nozzles in the fourth preliminary discharge range C5 and the sixth preliminary discharge range C7 (step S343). Thereby, one layer of the support material is formed in all the regions in the width direction of the fourth preliminary discharge range C5 and the sixth preliminary discharge range C7. The layer of the support material forms a part of the second sub-modeled object 922C. As described above, the fourth preliminary discharge range C5 and the sixth preliminary discharge range C7 are support material preliminary discharge ranges in which the support material is preliminary discharged.

  Thereafter, the moving mechanism 60C further moves the modeling stage S forward, and the modeling stage S is arranged at the front end.

  Next, the moving mechanism 60C moves the modeling stage S from the front end toward the rear. Accordingly, the modeling stage S passes again below the second ejection head 22C. The second ejection head 22C ejects droplets of the support material toward the upper surface of the modeling stage S that passes below based on the divided data (step S35).

  As shown in FIG. 15, step S35 includes a support material preliminary discharge step (step S351), a support material main discharge step (step S352), and a support material preliminary discharge step (step S353).

  In step S351, first, the second ejection head 22C ejects support material droplets from all nozzles in the sixth preliminary ejection range C7 and the fourth preliminary ejection range C5 (step S351). Thereby, another layer of the support material is formed in all the regions in the width direction of the sixth preliminary discharge range C7 and the fourth preliminary discharge range C5.

  Next, the second ejection head 22C ejects droplets of the support material based on the divided data in the three-dimensional object formation range C1 (step S352). Thereby, one layer of support material corresponding to the shape of each height position of the design data is formed.

  Subsequently, the second ejection head 22C ejects droplets of the support material from all the nozzles in the third preliminary ejection range C4 and the first preliminary ejection range C2 (step S353). Thereby, another layer of the support material is formed in all the regions in the width direction of the third preliminary discharge range C4 and the first preliminary discharge range C2.

  Thereafter, the moving mechanism 60C moves the modeling stage S further rearward. As a result, the upper surface of the liquid support material layer formed in steps S34 and S35 comes into contact with the outer peripheral surface of the second roller 32C. As a result, the upper surface of the support material is flattened by the second roller 32C (step S36).

  When the layer of the support material is flattened, subsequently, the moving mechanism 60C moves the modeling stage S further rearward and passes under the irradiation unit 40C. The irradiation unit 40 irradiates ultraviolet rays toward the modeling stage S that passes below (step S37). Thereby, the layer of the support material formed on the upper surface of the modeling stage S is cured.

  Thereafter, the moving mechanism 60C moves the modeling stage S further rearward. As a result, the modeling stage S passes again below the first ejection head 21C. 21 C of 1st discharge heads discharge the droplet of a model material toward the upper surface of the modeling stage S which passes below based on the divided | segmented data (step S38).

  As shown in FIG. 16, step S38 includes a model material preliminary discharge step (step S381), a model material main discharge step (step S382), and a model material preliminary discharge step (step S383).

  In step S38, first, the first discharge head 21C discharges droplets of the model material from all nozzles in the fifth preliminary discharge range C6 (step S381). Thereby, one layer of the model material is formed in all regions in the width direction of the fifth preliminary discharge range C6.

  Next, the first ejection head 21C ejects a droplet of a model material based on the divided data in the three-dimensional object formation range C1 (step S382). As a result, one layer of model material corresponding to the shape of each height position of the design data is formed.

  Subsequently, the first discharge head 21C discharges droplets of the model material from all the nozzles in the second preliminary discharge range C3 (step S383). Thereby, one layer of the model material is formed in all regions in the width direction of the second preliminary discharge range C3.

  Then, the moving mechanism 60C moves the modeling stage S further rearward. As a result, the upper surface of the liquid model material layer formed in step S38 comes into contact with the outer peripheral surface of the first roller 31C. As a result, the upper surface of the model material layer is flattened by the first roller 31C (step S39).

  Thereafter, the modeling stage S is arranged at the rear end. Then, at the rear end, the elevating mechanism 50C lowers the modeling stage S by the height of two material layers (step S40).

  Subsequently, the control unit 100C confirms whether or not there is a next material layer to be stacked (step S41). If there is a next material layer to be laminated, the process returns to step S32, and the processing of steps S32 to S38 is repeated to further laminate the material layer. On the other hand, when the lamination of all the material layers is completed, the process proceeds to step S42.

  In step S42, the moving mechanism 60C moves the modeling stage S forward and passes under the first roller 31C and the first discharge head 21C. Subsequently, the moving mechanism 60C passes the modeling stage S below the irradiation unit 40C. The irradiation unit 40C irradiates ultraviolet rays toward the modeling stage S that passes below. Thereby, the layer of the model material formed on the upper surface of the modeling stage S in step S38 is cured. Thus, the stacking process of the present embodiment is completed.

  In the present embodiment, the model material and the support material are discharged on both the forward path from the rear to the front and the return path from the front to the rear. Further, preliminary discharge ranges C3 and C6 for the model material and preliminary discharge ranges C2, C4, C5 and C7 for the support material are provided both in front of and behind the three-dimensional object formation range C1. As a result, the first discharge head 21 </ b> C makes the model material in either the second preliminary discharge range C <b> 3 or the fifth preliminary discharge range C <b> 6 before the main discharge of the model material in the three-dimensional object formation range C <b> 1 for each layer. Perform preliminary discharge. In addition, the second ejection head 22C has the first preliminary ejection range C2 and the third preliminary ejection range C4 or the fourth preliminary ejection range before the main ejection of the support material in the three-dimensional object formation range C1 for each layer. The support material is preliminarily discharged in either the C5 or the sixth predischarge range C7. As described above, in each of the ejection heads 21C and 22C, the ejection failure in the main ejection can be further suppressed by performing the preliminary ejection immediately before the main ejection for forming the main shaped article 91C. Therefore, the molding accuracy of the final model can be further improved.

<4. Modification>
As mentioned above, although main embodiment of this invention was described, this invention is not limited to said embodiment.

  In the laminating apparatus of the above-described embodiment, the model material and the support material are cured by one irradiation unit disposed between the two ejection heads. Therefore, the number of expensive irradiation parts can be suppressed. As a result, the manufacturing cost of the laminating apparatus and the three-dimensional modeling apparatus can be reduced, and the size can be reduced. However, the present invention is not limited to this. There may be a plurality of curing units that perform the curing process of the modeling material.

  In the above embodiment, the first discharge head that discharges the model material and the second discharge head that discharges the support material are each single. However, the number of the first ejection heads and the second ejection heads may be plural.

  In the above embodiment, the preliminary discharge process is performed in both the first discharge head that discharges the model material and the second discharge head that discharges the support material. However, the preliminary ejection step may be performed with only one ejection head. Depending on the material of the model material and the support material and the shape of the main modeled object, the likelihood of nozzle clogging between the first ejection head and the second ejection head differs. For this reason, for example, when nozzle clogging is likely to occur in the first ejection head that ejects the model material and nozzle clogging is less likely to occur in the second ejection head that ejects the support material, the preliminary ejection process is performed only with the first ejection head. Also good.

  In the above embodiment, the height of the processing unit including the first ejection head, the second ejection head, the roller, and the irradiation unit is fixed. The lifting mechanism moves the modeling stage up and down with respect to the processing unit. However, the elevating mechanism may move the processing unit up and down with respect to the modeling stage whose height is fixed. That is, the raising / lowering mechanism should just be what moves a modeling stage up and down relatively with respect to a processing unit.

  In the above-described embodiment, the position in the front-rear direction of the processing unit including the first discharge head, the second discharge head, the roller, and the irradiation unit is fixed. The moving mechanism reciprocates the modeling stage back and forth with respect to the processing unit. However, the moving mechanism may reciprocate the processing unit back and forth with respect to the modeling stage whose position in the front-rear direction is fixed. That is, the moving mechanism only needs to reciprocate the modeling stage relative to the processing unit in the horizontal direction.

  In the above embodiment, the model material and the support material are ultraviolet curable materials. However, the model material and the support material may be energy curable materials that are cured by energy other than ultraviolet rays, such as heat, infrared rays, laser, and X-rays. And an irradiation part may irradiate energy rays, such as a heat | fever, infrared rays, a laser, and an X-ray | X_line.

  In the above-described embodiment, the main model including the final model and the sub-model formed by the preliminary discharge process are formed at intervals in the transport direction. That is, the main modeled object and the sub-modeled object were formed separately. Thereby, it is easy to remove the support material for each of the main modeled object and the sub-modeled object. However, the main modeled object and the sub-modeled object may be formed so as to be connected in the transport direction.

  Further, the detailed shape and structure of the laminating apparatus and the three-dimensional modeling apparatus may be different from the shapes and structures shown in the drawings of the present application. Moreover, you may combine suitably each element which appeared in said embodiment and modification in the range which does not produce inconsistency.

DESCRIPTION OF SYMBOLS 1 3D modeling apparatus 9, 9B, 9C Three-dimensional object 10, 10C Laminating apparatus 20 Laminating part 21, 21C 1st discharge head 22, 22C 2nd discharge head 31, 31C, 32, 32C Roller 40, 40C Irradiation part 60, 60C Movement mechanism 91, 91B, 91C Main model 92B, 921, 921C, 922, 922C Sub model 900 Final model A1, B1, C1 Three-dimensional object formation range A2, A3, B2, B3, B4, C2, C3, C4 , C5, C6, C7 Pre-discharge range S Modeling stage

Claims (13)

A three-dimensional modeling apparatus that stacks modeling materials to form a three-dimensional object,
A modeling stage on which a material layer made of modeling material is formed,
A stacking portion for discharging the liquid modeling material onto the modeling stage to form the material layer;
A curing unit that performs a curing process on the material layer on the modeling stage;
A moving mechanism for relatively moving the modeling stage, the stacking unit, and the curing unit in a transport direction;
Have
The laminated portion is
With respect to the modeling stage that moves relatively in the transport direction, it has one or more ejection heads that eject the modeling material from a plurality of nozzles arranged in the width direction,
Each of the discharge heads discharges the modeling material to a three-dimensional object formation range that is a predetermined conveyance direction range on the modeling stage, and forms the material layer that constitutes the three-dimensional object. A three-dimensional modeling apparatus that discharges the modeling material from all the nozzles of the ejection head in a preliminary ejection range that is a conveyance direction range on the modeling stage different from a three-dimensional object formation range. The three-dimensional modeling apparatus according to claim 1,
Each of the discharge heads discharges the modeling material in the preliminary discharge range before discharging the modeling material in the three-dimensional object formation range when discharging each layer of the material layer. The three-dimensional modeling apparatus according to claim 1 or 2,
A plurality of ejection heads;
The plurality of ejection heads are
A model material discharge head for discharging a liquid model material from the plurality of nozzles;
A support material discharge head for discharging a liquid support material from the plurality of nozzles;
Including
The preliminary discharge range includes a model material preliminary discharge range and a support material preliminary discharge range,
The model material discharge head discharges the model material from all the nozzles in the model material preliminary discharge range,
The three-dimensional modeling apparatus, wherein the support material discharge head discharges the support material from all the nozzles in the support material preliminary discharge range. The three-dimensional modeling apparatus according to claim 3,
The three-dimensional modeling apparatus, wherein the model material preliminary discharge range and the support material preliminary discharge range are arranged adjacent to each other in the transport direction. The three-dimensional modeling apparatus according to claim 3,
The three-dimensional modeling apparatus, wherein the model material preliminary discharge range is arranged adjacent to the two support material preliminary discharge ranges arranged on both sides in the conveyance direction and the conveyance direction. The three-dimensional modeling apparatus according to any one of claims 1 to 5,
The modeling material is an energy curable material,
The said hardening part is a three-dimensional modeling apparatus which irradiates an energy beam with respect to the said modeling material on the said modeling stage. The three-dimensional modeling apparatus according to claim 6,
The modeling material is an ultraviolet curable material,
The said hardening part is a three-dimensional modeling apparatus which irradiates the modeling material on the said modeling stage with an ultraviolet-ray. The three-dimensional modeling apparatus according to any one of claims 1 to 7,
A three-dimensional modeling apparatus, further comprising a roller for flattening the material layer before curing formed on the modeling stage. A three-dimensional modeling method for forming a three-dimensional object on a modeling stage by a three-dimensional modeling apparatus having a laminated part and a curing part,
The laminated portion is
With respect to the modeling stage that moves relatively in the transport direction, it has a discharge head that discharges a liquid modeling material from a plurality of nozzles arranged in the width direction,
A) The stacking unit discharges the liquid modeling material from the discharge head toward the modeling stage;
B) the curing unit curing the liquid modeling material on the modeling stage;
Repeatedly,
Said step A)
p) discharging the modeling material from all the nozzles of the ejection head to a preliminary ejection range which is a predetermined transport direction range on the modeling stage;
q) A step of discharging the modeling material from the discharge head to a three-dimensional object forming region which is a predetermined conveyance direction range on the modeling stage different from the preliminary discharge range, and forming a material layer constituting the three-dimensional object. When,
Including a three-dimensional modeling method. The three-dimensional modeling method according to claim 9,
In the step A), the step q) is a three-dimensional modeling method performed after the step p). The three-dimensional modeling method according to claim 9 or 10,
The ejection head is
A model material discharge head for discharging a liquid model material from the plurality of nozzles;
A support material discharge head for discharging a liquid support material from the plurality of nozzles;
Including
Said step A)
A1) discharging the liquid model material from the model material discharge head toward the modeling stage;
A2) a step of discharging the liquid support material from the support material discharge head toward the modeling stage;
Including at least one of
The step A1)
p1) discharging the model material from all the nozzles of the model material discharge head into the model material preliminary discharge range which is the preliminary discharge range;
q1) discharging the model material from the model material discharge head to the three-dimensional object formation region to form the material layer constituting the three-dimensional object;
Including
The step A2)
p2) discharging the support material from all the nozzles of the support material discharge head to the support material preliminary discharge range which is the preliminary discharge range and is in a transport direction range different from the model material preliminary discharge range;
q2) discharging the support material from the support material discharge head to the three-dimensional object modeling region to form the material layer constituting the three-dimensional object;
Including a three-dimensional modeling method. The three-dimensional modeling method according to claim 11,
The three-dimensional modeling method, wherein the model material preliminary discharge range and the support material preliminary discharge range are arranged adjacent to each other in the transport direction. The three-dimensional modeling method according to claim 11,
The model material preliminary discharge range is a three-dimensional modeling method in which the two support material preliminary discharge ranges arranged on both sides in the transport direction are arranged adjacent to the transport direction.

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