JP2019147326A - Manufacturing method of solid molding, and creation method of manufacturing data of solid molding - Google Patents

Abstract

To provide a manufacturing method of a solid molding capable of preventing contamination of a device caused by elution of a material forming a support part without lowering removal speed of the support part.SOLUTION: There is provided a manufacturing method of a solid molding for molding a model part and a support part for supporting the model part. In the manufacturing method of a solid molding, when molding a molding comprising the model part and the support part, a support part protective barrier having a prescribed height is molded separately, to the support part positioned on the outermost contour of the molding.SELECTED DRAWING: Figure 3

Description

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

As a technique for modeling a three-dimensional solid object, a technique called additive manufacturing (AM) is known.
This technique is a technique for modeling a three-dimensional object by calculating a cross-sectional shape sliced in the stacking direction, forming each layer according to the shape, and stacking the layers.
In recent years, a material jetting method that forms a three-dimensional solid object by laminating a photocurable resin has attracted attention among additive manufacturing techniques.
According to the material jetting method, when modeling a model part that is a model body, by shaping the support part that supports the model part, it is difficult to form in principle (for example, a shape having an overhang part, etc.) ) Can be modeled.

In addition, in the optical modeling technology using the inkjet method of the material jetting method, it is known to perform optical modeling by discharging each of a plurality of photocurable resin compositions having different types and physical properties from a nozzle in the form of fine droplets. ing. The molded article body is formed using a photocurable resin composition that forms a water-insoluble cured product, and the support portion is formed using a photocurable resin composition that forms a water-soluble cured product. And the method of removing a support part by melt | dissolving a support part in water after modeling is proposed (for example, refer patent document 1).
Furthermore, a method for producing a three-dimensional structure has been proposed in which the outer surface of the water-soluble support part is covered with a support shell made of a water-insoluble material (see, for example, Patent Document 2).

  An object of this invention is to provide the manufacturing method of the three-dimensional molded item which can prevent the contamination of the apparatus by elution of the material which forms a support part, without reducing the removal speed of a support part.

Means for solving the problems are as follows. That is,
The manufacturing method of the three-dimensional structure of the present invention is as follows:
It is a manufacturing method of a three-dimensional modeled object which models a model part and a support part which supports the model part,
When modeling a model consisting of the model part and the support part, the support part positioned at the outermost contour of the model is modeled by separating a support part protective wall having a predetermined height. To do.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the three-dimensional molded item which can prevent the contamination of the apparatus by the elution of the material which forms a support part can be provided, without reducing the removal speed of a support part.

Drawing 1 is a mimetic diagram showing an example of the principal part front of the manufacturing device of a solid modeling thing. FIG. 2A is a schematic diagram of an example in which a three-dimensional model to be modeled is represented by a three-dimensional model. FIG. 2B is a schematic diagram illustrating an example of a model that is to be formed by a model portion and a support portion. FIG. 2C is a schematic diagram illustrating a cross-sectional view of the shaped article of FIG. 2B. FIG. 3 is a schematic diagram illustrating an example of the three-dimensional structure according to the present embodiment. FIG. 4A is a schematic view of the three-dimensional structure of Example 1 as viewed from the front. FIG. 4B is a schematic view of the three-dimensional modeled object of Example 1 as viewed from above. FIG. 5A is a schematic view of the three-dimensional structure of Comparative Example 1 as viewed from the front. FIG. 5B is a schematic view of the three-dimensional structure of Comparative Example 1 as viewed from above. FIG. 6A is a schematic view of the three-dimensional structure of Comparative Example 2 as viewed from the front. FIG. 6B is a schematic view of the three-dimensional structure of Comparative Example 2 as viewed from above. FIG. 7 is a block diagram for explaining a control unit of the three-dimensional structure manufacturing apparatus. FIG. 8 is a block diagram illustrating an example of a hardware configuration of the modeling data creation device. FIG. 9 is a flowchart illustrating an example of a process for creating manufacturing data of a three-dimensional structure.

When the present inventors examined the three-dimensional molded item using the material jetting system, they found the following.
In the technique described in Patent Document 1, since the material for forming the support part is eluted during or after modeling, the modeling stage is contaminated.
On the other hand, the technique described in Patent Document 2 may prevent contamination of the modeling stage due to the elution of the material forming the support part, but has a problem that the removal speed of the support part is significantly reduced.
Then, when modeling the modeling object which consists of a model part and a support part, the present inventors modeled the support part protective wall of predetermined height apart from the support part located in the outermost outline of a modeling object. . Such a support part protective wall can prevent contamination of the apparatus due to elution of the material forming the support part. Furthermore, in the presence of such a support part protection wall, a modeled object including a modeled model part and a support part can quickly remove the support part when the support part is removed from the modeled object.
That is, the manufacturing method of the three-dimensional structure of the present invention including the step of forming the support part protection wall prevents contamination of the apparatus due to elution of the material forming the support part without reducing the removal speed of the support part. The manufacturing method can be

(Method for manufacturing a three-dimensional model)
The manufacturing method of the three-dimensional molded item of this invention includes the process of modeling a model part and the support part which supports the said model part.
Moreover, the manufacturing method of the three-dimensional model | molding object of this invention is a support of predetermined height with respect to the said support part located in the outermost outline of the said model | molding object, when modeling the model | molding object which consists of the said model part and the said support part. Including a step of forming the part protection wall apart.
Specific contents of the above-described process of modeling the model part and the support part that supports the model part are, for example, as follows.
A liquid film made of a material forming the model part (hereinafter also referred to as model part forming material) and a liquid film made of a material forming the support part (hereinafter also referred to as support part forming material) are formed (film formation). Process). Next, the formed liquid film is cured (curing step). Then, the film formation and the curing are repeated a plurality of times, and the cured layer is stacked to form the model portion and the support portion.
Furthermore, the manufacturing method of the three-dimensional molded item of this invention may also include other processes as needed other than a smoothing process and a removal process.

<Process for modeling the model part and the support part>
The process of modeling the model part and the support part that supports the model part includes, for example, modeling the model part and the support part by repeating the following film forming process and the following curing process a plurality of times and laminating the cured layers. To do.
<< Film formation process >>
The film forming step is a step of forming a liquid film made of the model part forming material and a liquid film made of the support part forming material.
A specific embodiment of the film forming process will be described below. As described in the embodiment, the film forming process may be performed by using, for example, a model part forming material or a support part forming material from a liquid discharge head on a modeling stage. It discharges and forms by forming the layer which consists of modeling liquids. In this film forming step, a smoothing process for flattening the surface of the discharged modeling liquid with a roller or the like may be performed. The smoothing step will be described in detail in the section <Embodiment> below.
The model part forming material and the support part forming material will be described below.

<<< Model part forming material >>>
The model part forming material forms a liquid film constituting the model part.
The model part forming material can form a part constituting the model part.
In this invention, a model part means the part which comprises the main body which models the three-dimensional molded item of this invention.

  The liquid film constituting the model part can be obtained by appropriately selecting and imparting the model part forming material based on the performance required for constituting the main body for modeling the three-dimensional model. Moreover, content of the said model part formation material in the liquid film obtained can be suitably adjusted by providing a model part formation material in the same position.

The model part forming material is not particularly limited as long as it is a liquid that is cured by applying energy such as light and heat, and can be appropriately selected according to the purpose. The model part forming material preferably contains a polymerizable monomer such as a monofunctional monomer or a polyfunctional monomer, an oligomer, or a photopolymerization initiator, and further contains other components as necessary.
The model part forming material preferably has liquid properties such as viscosity and surface tension that can be discharged by a modeling material discharge head used in an inkjet printer or the like.

-Polymerizable monomer-
Examples of the polymerizable monomer include a monofunctional monomer and a polyfunctional monomer. These may be used individually by 1 type and may use 2 or more types together.

--Monofunctional monomer--
Examples of the monofunctional monomer include acrylamide, N-substituted acrylamide derivatives, N, N-disubstituted acrylamide derivatives, N-substituted methacrylamide derivatives, N, N-disubstituted methacrylamide derivatives, acrylic acid, and the like. These may be used individually by 1 type and may use 2 or more types together. Among these, acrylamide, N, N-dimethylacrylamide, N-isopropylacrylamide, acryloylmorpholine, hydroxyethylacrylamide, and isobornyl (meth) acrylate are preferable.

  There is no restriction | limiting in particular as monofunctional monomers other than the above, According to the objective, it can select suitably, For example, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meta) ) Acrylate, caprolactone-modified tetrahydrofurfuryl (meth) acrylate, 3-methoxybutyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, lauryl (meth) acrylate, 2-phenoxyethyl (meth) acrylate, isodecyl (meth) acrylate , Isooctyl (meth) acrylate, tridecyl (meth) acrylate, caprolactone (meth) acrylate, ethoxylated nonylphenol (meth) acrylate, and the like.

--Multifunctional monomer--
There is no restriction | limiting in particular as a polyfunctional monomer, According to the objective, it can select suitably, For example, a bifunctional monomer, a trifunctional or more monomer, etc. are mentioned. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the bifunctional monomer include tripropylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate, neopentyl glycol hydroxypivalate ester di (Meth) acrylate, hydroxypivalic acid neopentyl glycol ester di (meth) acrylate, 1,3-butanediol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di ( (Meth) acrylate, 1,9-nonanediol di (meth) acrylate, diethylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, tripropyleneglycol Rudi (meth) acrylate, caprolactone-modified hydroxypivalic acid neopentyl glycol ester di (meth) acrylate, propoxylated opentyl glycol di (meth) acrylate, ethoxy-modified bisphenol A di (meth) acrylate, polyethylene glycol 200 di (meth) acrylate And polyethylene glycol 400 di (meth) acrylate. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the tri- or higher functional monomer include trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, triallyl isocyanurate, ε-caprolactone modified dipentaerythritol tri ( (Meth) acrylate, ε-caprolactone-modified dipentaerythritol tetra (meth) acrylate, ε-caprolactone-modified dipentaerythritol penta (meth) acrylate, ε-caprolactone-modified dipentaerythritol hexa (meth) acrylate, tris (2-hydroxyethyl) Isocyanurate tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, propoxylated trimethylolpropane tri (meth) ) Acrylate, propoxylated glyceryl tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, ditrimethylolpropane tetra (meth) acrylate, dipentaerythritol hydroxypenta (meth) acrylate, ethoxylated pentaerythritol tetra (meth) acrylate, penta (Meth) acrylate ester etc. are mentioned. These may be used individually by 1 type and may use 2 or more types together.

-Oligomer-
As the oligomer, a low polymer of the above monomer or one having a reactive unsaturated bond group at the terminal may be used alone, or two or more may be used in combination.

-Photopolymerization initiator-
As the photopolymerization initiator, any substance that generates radicals upon irradiation with light (particularly, ultraviolet rays having a wavelength of 220 nm to 400 nm) can be used.
Examples of the photopolymerization initiator include acetophenone, 2,2-diethoxyacetophenone, p-dimethylaminoacetophenone, benzophenone, 2-chlorobenzophenone, p, p′-dichlorobenzophenone, p, p-bisdiethylaminobenzophenone, Michler's ketone, Benzyl, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-propyl ether, benzoin isobutyl ether, benzoin-n-butyl ether, benzyl methyl ketal, thioxanthone, 2-chlorothioxanthone, 2-hydroxy-2- Methyl-1-phenyl-1-one, 1- (4-isopropylphenyl) 2-hydroxy-2-methylpropan-1-one, methylbenzoylpho Mate, 1-hydroxycyclohexyl phenyl ketone, azobisisobutyronitrile, benzoyl peroxide, di-tert-butyl peroxide and the like. These may be used individually by 1 type and may use 2 or more types together.

-Other ingredients-
There is no restriction | limiting in particular as another component, According to the objective, it can select suitably, For example, surfactant, a polymerization inhibitor, a coloring agent etc. are mentioned.

--Surfactant--
As the surfactant, for example, a molecular weight of 200 or more and 5,000 or less, specifically, a PEG type nonionic surfactant [nonylphenol ethylene oxide (hereinafter abbreviated as EO) 1 to 40 mol adduct, stearic acid EO1 -40 mol adducts, etc.], polyhydric alcohol type nonionic surfactants (sorbitan palmitic acid monoester, sorbitan stearic acid monoester, sorbitan stearic acid triester, etc.), fluorine-containing surfactants (perfluoroalkyl EO 1-50) Mole adducts, perfluoroalkyl carboxylates, perfluoroalkyl betaines, etc.), modified silicone oils [polyether-modified silicone oil, (meth) acrylate-modified silicone oil, etc.] and the like. These may be used individually by 1 type and may use 2 or more types together.

--- Polymerization inhibitor ---
Examples of the polymerization inhibitor include phenol compounds [hydroquinone, hydroquinone monomethyl ether, 2,6-di-t-butyl-p-cresol, 2,2-methylene-bis- (4-methyl-6-t-butylphenol). 1,1,3-tris- (2-methyl-4-hydroxy-5-t-butylphenyl) butane, etc.], sulfur compounds [dilauryl thiodipropionate, etc.], phosphorus compounds [triphenyl phosphite, etc.] And amine compounds [phenothiazine and the like]. These may be used individually by 1 type and may use 2 or more types together.

--Colorant--
As the colorant, dyes and pigments that are dissolved or stably dispersed in the model part forming material and further excellent in thermal stability are suitable. Among these, a soluble dye (Solvent Dye) is preferable. Also, two or more kinds of colorants can be mixed in a timely manner by adjusting the color.

The viscosity of the model part forming material is preferably 5 mPa · s or more and 20 mPa · s or less, and more preferably 9 mPa · s or more and 13 mPa · s or less.
During three-dimensional modeling, the viscosity of the model part forming material can be adjusted by adjusting the temperature of the heater, preheater, or the like.

<<< Support part forming material >>>
The support part forming material forms a liquid film that constitutes the support part.
The support part forming material can form a part constituting the support part.
In the present invention, the support portion is disposed in a portion supporting the model portion in the gravitational direction in order to hold the three-dimensional structure in a predetermined position until the model portion is solidified, and is in contact with the model portion. It means the part that supports the model part from below.
The liquid film constituting the support part can be obtained by appropriately selecting and applying the model part forming material based on the function of supporting the model part in the direction of gravity of the model part.

The support part forming material is a liquid that is cured by applying energy such as light or heat, and is not particularly limited as long as a cured product obtained by curing the liquid is a material that collapses when immersed in a solvent. The support portion forming material can be appropriately selected according to the purpose, but the cured product is preferably water-disintegrating from the viewpoint of removal cost. Specifically, for example, the support part forming material preferably includes a monomer (A) having hydrogen bonding ability, a hydrogen bonding polymer (C), and a photopolymerization initiator (D). Moreover, it is more preferable that the solvent (B) which has hydrogen bonding ability, and also other components (E) as needed are included. It contains a monomer (A) having hydrogen bonding ability, a solvent (B) having hydrogen bonding ability, a hydrogen bonding polymer (C), and a photopolymerization initiator (D), and if necessary, other components (E) It is particularly preferable that
The support portion forming material preferably has liquid properties such as viscosity and surface tension that can be discharged by a modeling material discharge head used in an inkjet printer or the like.

-Monomer (A) having hydrogen bonding ability-
The monomer (A) having hydrogen bonding ability is not particularly limited as long as it has hydrogen bonding ability, and can be appropriately selected according to the purpose. For example, polymerization that undergoes radical polymerization by irradiation with active energy rays such as ultraviolet rays. And monofunctional monomers and polyfunctional monomers having properties. These may be used individually by 1 type and may use 2 or more types together.

  Examples of the monomer (A) having hydrogen bonding ability include monomers having an amide group, amino group, hydroxyl group, tetramethylammonium group, silanol group, epoxy group, sulfo group, and the like.

  Examples of the polymerization reaction of the monomer (A) having hydrogen bonding ability include radical polymerization, ionic polymerization, coordination polymerization, and ring-opening polymerization. Among these, radical polymerization is preferable from the viewpoint of controlling the polymerization reaction. Therefore, the monomer (A) having hydrogen bonding ability is preferably an ethylenically unsaturated monomer, more preferably a water-soluble monofunctional ethylenically unsaturated monomer or a water-soluble polyfunctional ethylenically unsaturated monomer, and has a hydrogen bonding ability. From the viewpoint of high points, water-soluble monofunctional ethylenically unsaturated monomers are particularly preferable.

--Water-soluble monofunctional ethylenically unsaturated monomer having hydrogen bonding ability--
The water-soluble monofunctional ethylenically unsaturated monomer having hydrogen bonding ability is not particularly limited and may be appropriately selected depending on the purpose. For example, a monofunctional vinylamide group-containing monomer [N-vinyl-ε-caprolactam, N-vinylformamide, N-vinylpyrrolidone and the like]; monofunctional hydroxyl group-containing (meth) acrylate [hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, 4-hydroxybutyl (meth) acrylate etc.]; hydroxyl group-containing (meta ) Acrylate [polyethylene glycol mono (meth) acrylate, monoalkoxy (C1-4) polyethylene glycol mono (meth) acrylate, polypropylene glycol mono (meth) acrylate, monoalkoxy (C1-4) polypropylene glycol mono (meta Acrylate, mono (meth) acrylate of PEG-PPG block polymer, etc.]; (meth) acrylamide derivatives [(meth) acrylamide, N-methyl (meth) acrylamide, N-ethyl (meth) acrylamide, N-propyl (meth) acrylamide N-butyl (meth) acrylamide, N, N′-dimethyl (meth) acrylamide, N-hydroxyethyl (meth) acrylamide, N-hydroxypropyl (meth) acrylamide, N-hydroxybutyl (meth) acrylamide and the like], ( And (meth) acryloylmorpholine. These may be used individually by 1 type and may use 2 or more types together.
Among these, from the viewpoint of photoreactivity, monofunctional hydroxyl group-containing (meth) acrylate, hydroxyl group-containing (meth) acrylate, and (meth) acrylamide derivatives are preferable. Hydroxyethyl acrylate, hydroxypropyl acrylate, 4-hydroxybutyl acrylate, acrylamide, acryloylmorpholine, N-methylacrylamide, N-ethylacrylamide, N-propylacrylamide, N-butylacrylamide, N, N′-dimethylacrylamide, N-hydroxy Ethyl acrylamide, N-hydroxypropyl acrylamide, N-hydroxybutyl acrylamide, and diethyl acrylamide are more preferable. From the viewpoint of low skin irritation to the human body, acryloylmorpholine (molecular weight: 141.17) and N-hydroxyethylacrylamide (molecular weight: 115.15) are particularly preferred.

--Water-soluble polyfunctional ethylenically unsaturated monomer having hydrogen bonding ability--
The water-soluble polyfunctional ethylenically unsaturated monomer having hydrogen bonding ability is not particularly limited and can be appropriately selected depending on the purpose. For example, water-soluble difunctional ethylenically unsaturated monomer, water-soluble trifunctional ethylene Unsaturated unsaturated monomers.
There is no restriction | limiting in particular as a water-soluble bifunctional ethylenically unsaturated monomer, According to the objective, it can select suitably, For example, a tripropylene glycol di (meth) acrylate, a triethylene glycol di (meth) acrylate, tetraethylene Glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate, neopentyl glycol hydroxypivalate ester di (meth) acrylate, hydroxypivalate neopentyl glycol ester di (meth) acrylate, 1,3-butanediol di (meth) Acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, diethylene glycol di (meth) acrylate , Neopentyl glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, caprolactone-modified hydroxypivalic acid neopentyl glycol ester di (meth) acrylate, propoxylated opentyl glycol di (meth) acrylate, polyethylene glycol 200 Examples include di (meth) acrylate and polyethylene glycol 400 di (meth) acrylate.
The water-soluble trifunctional ethylenically unsaturated monomer is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include triallyl isocyanate and tris (2-hydroxyethyl) isocyanurate tri (meth) acrylate. Can be mentioned. These may be used individually by 1 type and may use 2 or more types together.

  The molecular weight of the monomer (A) having hydrogen bonding ability is preferably 70 or more and 2,000 or less, and more preferably 100 or more and 500 or less. When the molecular weight is 70 or more and 2,000 or less, the viscosity can be adjusted to be optimal for the ink jet system.

  As content of the monomer (A) which has hydrogen bonding ability, 30 mass% or more and 60 mass% or less are preferable with respect to the support part formation material whole quantity. When the content is 30% by mass or more and 60% by mass or less, sufficient compressive stress and water disintegration can be achieved as a support part for supporting the shape of the model part.

-Solvent (B) having hydrogen bonding ability-
The solvent (B) having hydrogen bonding ability has a hydrogen bonding ability with the monomer (A) having hydrogen bonding ability, and forms a hydrogen bond with the monomer (A) having hydrogen bonding ability, thereby supporting the shape support. The function of the part can be demonstrated. The solvent (B) having hydrogen bonding ability is preferably liquid at 25 ° C.

The solvent (B) having a hydrogen bonding ability is not particularly limited as long as it is a solvent having a hydrogen bonding ability, and can be appropriately selected according to the purpose. For example, a diol having 3 to 6 carbon atoms, a monoalcohol having 6 or more carbon atoms, a cyclic alcohol having 6 or more carbon atoms, a polypropylene glycol monoether having 6 or more carbon atoms, a carboxylic acid compound, an amine compound, an ester compound, a ketone compound, Examples include urea compounds. These may be used individually by 1 type and may use 2 or more types together.
Among these, a diol having 3 to 6 carbon atoms and a monoalcohol having 6 or more carbon atoms are preferable.

--Diol having 3 to 6 carbon atoms--
The diol having 3 to 6 carbon atoms has no reactivity with the water-soluble acrylic monomer, does not inhibit the radical polymerization reaction at the time of curing, is fluid at room temperature, and is a water-soluble material. Is preferred. Further, as the diol having 3 to 6 carbon atoms, both monofunctional and polyfunctional can be used.
The diol having 3 to 6 carbon atoms is not particularly limited and may be appropriately selected depending on the purpose. For example, propanediol, butanediol, pentanediol, hexanediol and the like can be mentioned. These may be used individually by 1 type and may use 2 or more types together.
Among these, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, and 1,6-hexanediol are preferable.

The diol having 3 to 6 carbon atoms has 3 to 6 carbon atoms, preferably 3 to 5 carbon atoms. When the number of carbon atoms is 3 or more, the compressive stress during 1% compression can be improved in an environment of 25 ° C. When the carbon number is 6 or less, the viscosity of the support portion forming material can be lowered.
The carbon chain of the diol having 3 to 6 carbon atoms may be linear or branched.

  The content of the diol having 3 to 6 carbon atoms is preferably 5% by mass or more and 60% by mass or less, and more preferably 15% by mass or more and 50% by mass or less with respect to the total amount of the support portion forming material. When the content is 5% by mass or more and 60% by mass or less, both sufficient compressive stress as a support part for supporting the shape of the model part and water disintegration can be achieved.

--Monoalcohol having 6 or more carbon atoms--
A monoalcohol having 6 or more carbon atoms is hydrophobic, has a large number of carbon atoms, and the cured product to be formed can be hardened by the orientation or entanglement of the alkyl chain.
The monoalcohol having 6 or more carbon atoms is not particularly limited and may be appropriately selected depending on the purpose. Examples thereof include higher alcohols, cyclic alcohols, monoalcohols containing alkylene oxide groups, and the like. These may be used individually by 1 type and may use 2 or more types together.
Examples of the higher alcohol include 1-hexanol, 1-decanol, 1-dodecanol and the like.
Examples of the cyclic alcohol include cyclohexanol and cyclopentanol.
Examples of the alkylene oxide group in the monoalcohol containing an alkylene oxide group include an ethylene oxide group and a propylene oxide group.

Examples of the structure of the monoalcohol having 6 or more carbon atoms include a chain structure and a cyclic structure.
The chain structure may be a linear structure or a structure having a branched chain. Among these, from the viewpoint of hydrogen bonding ability, a monoalcohol having a chain structure is preferable, and a monoalcohol having a linear structure is more preferable.
The upper limit of the carbon number of the monoalcohol having 6 or more carbon atoms is not particularly limited and may be appropriately selected according to the purpose such as water disintegration, but is preferably 20 or less, and more preferably 12 or less.
The monoalcohol having 6 or more carbon atoms preferably has no reactivity with the water-soluble acrylic monomer, does not inhibit the radical polymerization reaction during photocuring, and has fluidity at room temperature.

  As content of C6 or more monoalcohol, 20 mass% or more and 70 mass% or less are preferable with respect to the support part formation material whole quantity. When the content is 20% by mass or more and 70% by mass or less, sufficient compressive stress and water disintegration can be achieved as a support part for supporting the shape of the model part.

--Carboxylic acid compound--
There is no restriction | limiting in particular as a carboxylic acid compound, According to the objective, it can select suitably, For example, a linear aliphatic carboxylic acid, branched-chain aliphatic carboxylic acid, aromatic carboxylic acid, hydroxycarboxylic acid etc. are mentioned. .
Examples of the linear aliphatic carboxylic acid include formic acid, acetic acid, propionic acid, butanoic acid, pentanoic acid, hexyl acid and the like.
Examples of the branched aliphatic carboxylic acid include isobutyric acid, t-butyric acid, isopentylic acid, isooctylic acid, 2-ethylhexylic acid, and the like.
Examples of the aromatic carboxylic acid include benzoic acid and benzenesulfonic acid.
Examples of the hydroxycarboxylic acid include glycolic acid and lactic acid.
These may be used individually by 1 type and may use 2 or more types together. Among these, from the viewpoint of solubility in water, acetic acid, propionic acid, butanoic acid, and lactic acid are preferable, and butanoic acid and lactic acid are more preferable.

--Amine compound--
There is no restriction | limiting in particular as an amine compound, According to the objective, it can select suitably, For example, monovalent | monohydric primary-tertiary amine, bivalent primary amine, trivalent primary amine, aliphatic amine Etc.
Examples of monovalent primary to tertiary amines include monoalkylamines, dialkylamines, and trialkylamines.
Examples of the divalent primary amine include ethylenediamine.
Examples of the trivalent primary amine include triethylenediamine.
Examples of the aliphatic amine include pyridine and aniline.
These may be used individually by 1 type and may use 2 or more types together. Among these, a divalent primary amine and a trivalent primary amine are preferable, and ethylenediamine is more preferable from the viewpoint of crosslinking strength due to hydrogen bonding and solubility in water.

--Ester compound--
There is no restriction | limiting in particular as an ester compound, According to the objective, it can select suitably, For example, monofunctional ester, polyfunctional aliphatic ester, polyfunctional aromatic ester etc. are mentioned.
Examples of the monofunctional ester include ethyl acetate, butyl acetate, and ethyl propionate.
Examples of the polyfunctional aliphatic ester include dimethyl succinate and dimethyl adipate.
Examples of the polyfunctional aromatic ester include dimethyl terephthalate.
These may be used individually by 1 type and may use 2 or more types together. Among these, dimethyl adipate is preferable from the viewpoints of solubility in water, evaporation and odor during three-dimensional modeling, and safety.

-Ketone compound-
There is no restriction | limiting in particular as a ketone compound, According to the objective, it can select suitably, For example, a monofunctional ketone, a polyfunctional ketone, etc. are mentioned.
Examples of the monofunctional ketone include acetone and methyl ethyl ketone.
Examples of the polyfunctional ketone include acetylacetone and 2,4,6-heptatrione.
These may be used individually by 1 type and may use 2 or more types together. Among these, acetylacetone is preferable from the viewpoints of volatility and solubility in water.

  As content of the solvent (B) which has hydrogen bonding ability, 10 mass% or more and 50 mass% or less are preferable with respect to the support part formation material whole quantity. When the content is 10% by mass or more and 50% by mass or less, sufficient compressive stress and water disintegration can be achieved as a support part for supporting the shape of the model part.

-Hydrogen bonding polymer (C)-
The hydrogen bonding polymer (C) is a material that is not reactive with water-soluble acrylic monomers, does not inhibit radical polymerization reaction during photocuring, has fluidity at room temperature, and is soluble in water. Is preferred.

There is no restriction | limiting in particular as a hydrogen bondable polymer (C), According to the objective, it can select suitably, For example, an active hydrogen compound etc. are mentioned.
There is no restriction | limiting in particular as an active hydrogen compound, According to the objective, it can select suitably, For example, a monofunctional compound, a polyfunctional compound, etc. are mentioned.
Examples of the monofunctional compound include alcohol, ether, amide, ester and the like.

Specific examples of the active hydrogen compound include alkylene oxide adducts, monovalent to tetravalent alcohols, and amine compounds. Among these, alkylene oxide adducts and monovalent to divalent alcohols are preferred.
Examples of the alkylene oxide adduct include polypropylene glycol, polyethylene glycol, and polypropylene glycol monobutyl ether.

The number average molecular weight of the hydrogen bonding polymer (C) is preferably 400 or more in consideration of the rate of change in the height of the support portion when cured and the solubility in water, and is preferably 400 or more and 5,000 or less. More preferably, 400 or more and 2,000 or less are particularly preferable.
The number average molecular weight can be measured using, for example, gel permeation chromatography (GPC).

  The content of the hydrogen bonding polymer (C) is preferably 10% by mass or more and 50% by mass or less, and preferably 25% by mass or more and 50% by mass or less with respect to the total amount of the support part forming material, from the viewpoint of solubility in water. Is more preferable.

-Photopolymerization initiator (D)-
As the photopolymerization initiator (D), any substance that generates radicals upon irradiation with light (particularly, ultraviolet light having a wavelength of 220 nm to 400 nm) can be used, and a photopolymerization initiator that matches the ultraviolet wavelength of the ultraviolet irradiation device is used. It is preferable to select.
As the photopolymerization initiator of the support portion forming material, the same photopolymerization initiator as the model portion forming material can be used.

  As content of a photoinitiator (D), 0.5 mass% or more and 10 mass% or less are preferable with respect to the support part formation material whole quantity.

-Other components (E)-
There is no restriction | limiting in particular as another component, According to the objective, it can select suitably, For example, surfactant, a polymerization inhibitor, a coloring agent etc. are mentioned.

--Surfactant--
As the surfactant for the support portion forming material, for example, the same surfactant as that for the model portion forming material can be used.
As content of surfactant, 5 mass% or less is preferable with respect to support part formation material whole quantity. Further, from the viewpoint of improving the wetting and spreading of the support portion forming material and adjusting the surface roughness of the model portion at the interface between the model portion and the support portion, the content of the surfactant is 0.1% by mass or more and 3% by mass. The following is more preferable.

--- Polymerization inhibitor ---
As the polymerization inhibitor for the support portion forming material, for example, the same polymerization inhibitor as the model portion forming material can be used.
As content of a polymerization inhibitor, 10 mass% or less is preferable with respect to the support part formation material whole quantity, and 0.1 mass% or more and 5 mass% or less are more preferable from the point of the stability of a monomer and a polymerization rate.

--Colorant--
As the colorant, dyes and pigments that are dissolved or stably dispersed in the support portion forming material and further excellent in thermal stability are suitable. Among these, a soluble dye (Solvent Dye) is preferable. Also, two or more kinds of colorants can be mixed in a timely manner by adjusting the color.

The viscosity of the support portion forming material is preferably 5 mPa · s or more and 20 mPa · s or less, and more preferably 9 mPa · s or more and 13 mPa · s or less.
During three-dimensional modeling, the viscosity of the support portion forming material can be adjusted by adjusting the temperature of the heater, preheater, or the like.

<< Curing process >>
The curing step is a step of curing the liquid film formed in the film forming step.
Examples of the curing means used in the curing step include an ultraviolet (UV) irradiation lamp and an electron beam. The means for curing the liquid film is preferably provided with a mechanism for removing ozone.
Examples of the ultraviolet (UV) irradiation lamp include a high pressure mercury lamp, an ultrahigh pressure mercury lamp, a metal halide, and an LED.
The ultra-high pressure mercury lamp is a point light source, but the Deep UV type, which has high light utilization efficiency in combination with an optical system, can irradiate in a short wavelength region.
Metal halides are effective for colored materials because of their wide wavelength range, and metal halides such as Pb, Sn, and Fe are used and can be selected according to the absorption spectrum of the polymerization initiator.
There is no restriction | limiting in particular as a lamp | ramp used for hardening, According to the objective, it can select suitably, For example, commercial items, such as H lamp, D lamp, and V lamp made from Fusion System, etc. can be used.
When radically polymerizable monomers and oligomers are used as the curable liquid material, it is preferable that the oxygen concentration in the environment in which the film forming and curing processes are performed is low, for example, a space substituted with nitrogen or the like. Particularly preferred.

<< Modeling process of model part and support part >>
As described above, the modeling process of the model part and the support part is a process of modeling the model part and the support part by repeating the film forming process and the curing process a plurality of times and stacking the cured layers. .
The number of repetitions varies depending on the size, shape, etc. of the three-dimensional structure to be produced, and cannot be specified unconditionally, but the average thickness per layer is preferably 5 μm or more and 50 μm or less. When the average thickness is 5 μm or more and 50 μm or less, it is possible to form with accuracy and without peeling, and the three-dimensional object can be stacked by the height.

<Process for forming support part protective wall (support part protective wall forming process)>
The modeling process of the support part protection wall is performed by modeling the support part protection wall of a predetermined height away from the support part located at the outermost contour of the model object when modeling a model consisting of the model part and the support part. To do.
The support part protection wall may be formed at a predetermined height at a position separated by a predetermined distance from a support part located at the outermost contour of the modeled object including the model part and the support part. The support part protective wall can prevent contamination of the apparatus due to elution of the material forming the support part.
Here, it is important that a gap exists between the support part protection wall and the support part located at the outermost contour of the modeled object. Thereby, when removing a support part from the modeling thing which consists of a modeled model part and a support part, a support part can be removed rapidly.

In FIG. 3, an example of the three-dimensional molded item of this embodiment is shown. In FIG. 3, reference numeral 300 denotes a model part, reference numeral 310 denotes a support part, reference numeral 320 denotes a modeling stage, reference numeral 330 denotes a support part protection wall, and reference numeral 340 denotes a gap.
The surface of the support portion that faces the support portion protection wall of the support portion that is positioned at the outermost contour of the modeled object and the surface of the support portion protection wall that faces the support portion must be separated by an average distance of 1 mm or more. preferable. If it is 1 mm or more, the support part can be removed satisfactorily when the support part is removed by immersion in water. Here, the average distance refers to, for example, an average value of 10 points apart.
Moreover, if a support part protection wall can be formed on a modeling stage so that it may have predetermined | prescribed height, there will be no restriction | limiting in particular in a shape, and it can select according to the objective suitably.
Further, the separation distance may be appropriately set in consideration of the height and size of the support part in the modeled object, the height of the support part protection wall, and the like.

As a preferable aspect of the support part protection wall, for example, an aspect in which a model is formed as a continuous wall that surrounds the modeled object at a position separated from the outermost contour of the modeled object composed of the model part and the support part (position separated by a predetermined distance). Is mentioned.
Moreover, as a preferable shape of a support part protection wall, the shape of the container which the upper part opened is mentioned, for example, and the continuous wall and bottom face part which enclosed the molded article were integrally formed. More specifically, such a container has a box shape. The box shape is not particularly limited, and may be a quadrangle or a circle.
In the following embodiment, as shown in FIG. 3, a case will be described in which the support portion protection wall has a box shape. In this case, a modeled object having the model part and the support part is formed in the open container of the support part protection wall. Furthermore, in the box-shaped support part protective wall, a layer made of the support part forming material is formed on the inner surface of the bottom part of the support part protective wall, and a modeled object made of the model part and the support part is formed on the layer made of the support part forming material. It is good to model.
The height of the support part protection wall is not particularly limited as long as it can prevent the elution of the support part, but may be appropriately adjusted depending on the hygroscopicity and solubility conditions of the material forming the support part.
Preferably, the height is such that it does not leak when the entire support portion is eluted.
In addition, the constituent material of the support portion protection wall is not particularly limited as long as it is a material having a strength capable of preventing the elution of the support portion, but it is preferably formed of a model material forming material in consideration of modeling efficiency.

  There is no particular limitation on the modeling order of the modeled object having the model part and the support part and the support part protective wall, and the shape and size of the modeled object, the shape and size of the support part protective wall, etc. are considered as appropriate. Can be set. For example, when layering a modeled object layer by layer, the support part protection wall may be matched to the modeled object and a layer having the same height as the modeled object may be modeled. Or you may make it model a support part protection wall to some extent ahead, and to model the model part and the support part in the enclosure of a support part protection wall later.

<Removal process>
It is preferable that the manufacturing method of the three-dimensional molded item of this invention further includes a removal process.
A removal process is a process of removing a support part from the modeling object which consists of the formed model part and support part.

The removal process can be performed by auxiliary processes such as trimming, dissolving in liquid, removing by immersing in liquid, applying temperature, oscillating ultrasonically, and applying energy by stirring. These may be combined as appropriate.
Among these, a method of dissolving in a liquid is preferable, and a method of dissolving the support portion by being immersed in the liquid is more preferable.
Examples of the liquid include water and organic solvents.

<Other processes>
There is no restriction | limiting in particular as said other process, According to the objective, it can select suitably, For example, the grinding | polishing process of a molded object, the cleaning process of a molded object, etc. are mentioned.

<Embodiment>
Hereinafter, a specific mode of the manufacturing method of the three-dimensional modeled object of the present invention and a manufacturing apparatus (also referred to as a modeling apparatus in the present specification) for performing the manufacturing method will be described. However, the present invention is not limited to these embodiments.
The model part forming material and the support part forming material described above are mounted on the modeling apparatus of this embodiment.
The modeling apparatus of this embodiment is a general material jet type modeling apparatus using a model part forming material and a support part forming material having UV curing properties.

<< Manufacturing equipment (modeling equipment) >>
FIG. 1 is a schematic view showing a modeling apparatus according to an embodiment of the present invention. The modeling apparatus 30 includes head units 31 and 32, an ultraviolet irradiator 33, a roller 34, a carriage 35, and a stage 37. The head unit 31 discharges the model part forming material 1. The head unit 32 discharges the support portion forming material 2. The ultraviolet irradiator 33 irradiates the discharged model part forming material 1 and the support part forming material 2 with ultraviolet rays and cures them. The roller 34 smoothes the liquid films of the model part forming material 1 and the support part forming material 2. The carriage 35 reciprocates each unit such as the head units 31 and 32 in the X direction in FIG. The stage 37 moves the substrate 36 in the Z direction shown in FIG. 1 and the Y direction which is the depth direction in FIG. The movement in the Y direction may be performed not on the stage 37 but on the carriage 35.

When there are a plurality of model part forming materials for each color, the modeling apparatus 30 may be provided with a plurality of head units 31 for discharging the model part forming material of each color.
As nozzles in the head units 31 and 32, nozzles in known ink jet printers can be suitably used.

Examples of the metal that can be used for the roller 34 include SUS300 series, 400 series, 600 series, hexavalent chromium, silicon nitride, and tungsten carbide. Further, a metal in which any of these is coated with fluorine or silicone may be used for the roller 34. Among these metals, 600 series is preferable from the viewpoint of strength and workability.
When the roller 34 is used, the modeling apparatus 30 performs stacking while lowering the stage 37 in accordance with the number of stacking in order to keep the gap between the roller 34 and the surface of the modeled object constant. It is preferable that the roller 34 is adjacent to the ultraviolet irradiator 33.

  Further, in order to prevent the ink from drying during the pause, the modeling apparatus 30 may be provided with means such as a cap for closing the nozzles in the head units 31 and 32. In order to prevent nozzle clogging during continuous use for a long time, the modeling apparatus 30 may be provided with a maintenance mechanism for maintaining the head.

<< Method for creating manufacturing data of a three-dimensional structure >>
Manufacturing data (also referred to as modeling data in the present specification) for manufacturing a three-dimensional model is created by a modeling data creation device 600 as shown in FIG.
Hereinafter, a method for creating the manufacturing data will be briefly described. In addition, the further detailed description about the manufacturing data (modeling data) creation apparatus which produces manufacturing data, and a creation method is given in the column of the following (the production method of the manufacturing data of a solid modeling thing).

  FIG. 2A is a schematic diagram illustrating an example of a three-dimensional model in which a three-dimensional model to be modeled is represented by a three-dimensional model. The three-dimensional model 100 is, for example, three-dimensional data such as a three-dimensional shape designed by three-dimensional CAD, or three-dimensional surface data or solid data captured by a three-dimensional scanner or digitizer. The three-dimensional data may be converted into, for example, an STL format (Standard Triangulated Language) in which the surface of the three-dimensional model is expressed as a collection of triangles.

  In the modeling data creation device, the bottom surface is specified from the input three-dimensional data. The method for specifying the bottom surface is not particularly limited. For example, when the three-dimensional model is arranged in the three-dimensional coordinate system, the direction in which the length is the shortest is the Z axis, and the contact point between the surface orthogonal to the Z axis and the three-dimensional model is the bottom surface. .

The modeling data creation device generates two-dimensional data indicating a cut surface obtained by slicing a three-dimensional model in a direction parallel to the bottom surface at predetermined intervals in the Z-axis direction. In this case, the modeling data creation apparatus obtains the projected area of the three-dimensional model onto the XY plane, XZ plane, and YZ plane. In the modeling data creation device, the block shape in which the obtained projected area is accommodated is cut into slices (slices) parallel to the XY plane with a single layer thickness.
The thickness of one layer depends on the material used, but is usually about 20 μm or more and 60 μm or less.
Data processing such as generation of two-dimensional data may be automatically set in the modeling data creation device in accordance with designation of the material used.

In addition, when the three-dimensional model has an overhang portion as in the curved surface shown by gradation in FIG. 2A, the modeling data creation device generates data so as to model while supporting the model portion of the overhang portion with the support portion. create.
FIG. 2B is a schematic diagram illustrating an example of a model to be formed with a model unit and a support unit, and more specifically, an example of a model with the model unit 10 of the overhang unit supported by the support unit 20. It is a schematic diagram which shows.
In the modeling data creation device, a pixel indicating a support portion is added to the bottom surface side of the overhang portion for each generated two-dimensional data. The finally generated two-dimensional data indicates one section of the modeled object, and includes pixels indicating a model portion and pixels indicating a support portion.
FIG. 2C shows a schematic diagram showing a cross section of the shaped article of FIG. 2B.

<< Manufacturing method (modeling method) >>
Based on the manufacturing data described above, the manufacturing apparatus (modeling apparatus) models a three-dimensional model. Each manufacturing process performed by the manufacturing apparatus will be described below.

-Discharge process-
The engine of the modeling apparatus 30 moves the carriage 35 or the stage 37 and moves the model part forming material 1 from the head unit 31 based on the two-dimensional data indicating the cross section on the most bottom surface side among the input two-dimensional data. A droplet is ejected, and a droplet of the support portion forming material 2 is ejected from the head unit 32.
Thereby, the droplet of the model part forming material 1 is arranged at a position corresponding to the pixel indicating the model part in the two-dimensional data indicating the cross section on the most bottom side, and the support part forming material is positioned at the position corresponding to the pixel indicating the support part. Two liquid droplets are arranged to form a liquid film in which droplets at adjacent positions are in contact with each other.
In addition, when there is one model to be modeled, a liquid film having a cross-sectional shape is formed in the middle of the stage 37. When there are a plurality of modeling objects to be modeled, the modeling apparatus 30 may form a plurality of cross-sectional liquid films on the stage 37, or may stack the liquid films on the previously modeled modeling objects.

  The head units 31 and 32 are preferably provided with heaters. Furthermore, it is preferable to install a preheater on the path for supplying the model part forming material to the head unit 31 and the path for supplying the support part forming material to the head unit 32.

-Smoothing process-
In the smoothing step, the roller 34 is a liquid made of the model part forming material and the support part forming material by scraping off an excessive part of the model part forming material and the support part forming material discharged onto the stage 37. The unevenness of the film or layer is smoothed. The smoothing process may be performed once for each stack in the Z-axis direction, or may be performed once for every 2 to 50 stacks.
In the smoothing step, the roller 34 may be stopped, or may be rotated at a positive or negative relative speed with respect to the traveling direction of the stage 37. The rotation speed of the roller 34 may be constant, constant acceleration, or constant deceleration. The rotation speed of the roller 34 is preferably 50 mm / s or more and 400 mm / s or less as an absolute value of the relative speed with the stage 37. When the relative speed is too small, smoothing is insufficient and smoothness is impaired. On the other hand, if the relative speed is too high, the apparatus needs to be large, and the displacement of the ejected liquid droplets is likely to occur due to vibration or the like, resulting in a decrease in smoothness.
In the smoothing step, the rotation direction of the roller 34 is preferably opposite to the traveling direction of the head units 31 and 32.

-Curing process-
In the curing process, the engine of the modeling apparatus 30 moves the ultraviolet irradiator 33 by the carriage 35, and the photopolymerization included in the model part forming material and the support part forming material is formed in the liquid film formed in the liquid film forming process. Irradiate ultraviolet rays according to the wavelength of the initiator.
Thereby, the modeling apparatus 30 hardens | cures a liquid film and forms a layer.

-Lamination process-
After formation of the layer on the bottom side, the engine of the modeling apparatus 30 lowers the stage by one layer.
The engine of the modeling apparatus 30 discharges the droplet of the model part forming material 1 based on the two-dimensional image data indicating the second cross section from the bottom side while moving the carriage 35 or the stage 37, thereby supporting the support part. A droplet of the forming material 2 is discharged. The discharging method is the same as that for forming the liquid film on the bottom side. As a result, a liquid film having a cross-sectional shape indicated by the second two-dimensional data from the bottom surface side is formed on the most bottom layer. Further, the engine of the modeling apparatus 30 moves the ultraviolet irradiator 33 by the carriage 35 and irradiates the liquid film with ultraviolet rays to cure the liquid film, and on the layer on the bottom side, the second side from the bottom side. Form a second layer.

  The engine of the modeling apparatus 30 uses the input two-dimensional data in order from the one closer to the bottom surface side, repeats the formation of the liquid film and the curing, and stacks the layers in the same manner as described above. The number of repetitions varies depending on the number of input two-dimensional image data or the height and shape of the three-dimensional model. When the modeling using all the two-dimensional image data is completed, the modeled object of the model part supported by the support part is obtained.

-Removal process-
The modeled object modeled by the modeling apparatus 30 has a model part and a support part. The support part is removed from the modeled object after modeling. Removal methods include physical removal and chemical removal. In physical removal, mechanical force is applied for removal. On the other hand, in chemical removal, the support portion is collapsed and removed by dipping in a solvent. Although there is no restriction | limiting in particular as a removal method of a support part, Since a molded article may be damaged in physical removal, chemical removal is more preferable. Furthermore, considering the cost, a method of removing by immersing in water is more preferable. When the method of removing by immersing in water is adopted, a cured product of the support portion forming material is selected to have water disintegration.

(Method for creating manufacturing data of a three-dimensional structure)
The method for creating manufacturing data of a three-dimensional object according to the present invention is a procedure for modeling a three-dimensional model representing a three-dimensional object to be modeled from a model part and a support part that supports the model part, and A procedure is set for modeling the support part positioned at the outermost contour of the model by separating a support part protective wall having a predetermined height.
Manufacturing data (modeling data) is created by the modeling data creation device 600 as shown in FIG. The created modeling data is input to the modeling apparatus 30 for a three-dimensional model. Thereafter, the control unit 500 of the modeling apparatus 30 performs drive processing so as to model a three-dimensional modeled object according to the input modeling data. Thereby, in a modeling apparatus, a desired three-dimensional molded item is modeled.
In addition, even if modeling data does not create with the apparatus (modeling data creation apparatus 600) different from the modeling apparatus 30, as shown in FIG. 7, the modeling data creation part which has the function to create modeling data in the modeling apparatus 30 The modeling data may be created in the modeling apparatus 30.

First, before specifically describing creation of modeling data, the operation of the control unit 500 in the modeling apparatus 30 to which modeling data is input will be described with reference to FIG.
FIG. 7 is a block diagram for explaining a control unit of the three-dimensional structure manufacturing apparatus.

The control unit 500 includes a CPU 501 that controls the entire apparatus, a 3D modeling program that includes a program for causing the CPU 501 to execute a 3D modeling operation including control according to the present invention, and a ROM 502 that stores other fixed data. A main control unit 500A including a RAM 503 for temporarily storing modeling data and the like.
The control unit 500 also includes a non-volatile memory (NVRAM) 504 for holding data while the apparatus is powered off. Further, the control unit 500 includes an ASIC 505 that processes image processing for performing various signal processing on image data and other input / output signals for controlling the entire apparatus.
Further, the control unit 500 includes an I / F 506 for transmitting and receiving data and signals used when receiving modeling data from the external modeling data creating apparatus 600.
In FIG. 7, a modeling data creation device 600 is a device that creates modeling data (cross-sectional data) that is slice data obtained by slicing a final modeled object (three-dimensional modeled object) for each modeling layer. It consists of a processing device. A detailed description of the modeling data creation device will be described later.

The control unit 500 includes an I / O 507 for taking in detection signals of various sensors.
Further, the control unit 500 includes a head drive control unit 508 that drives and controls the liquid discharge head unit 31 and a head drive control unit 509 that drives and controls the head unit 32.
Further, the control unit 500 moves the liquid discharge head units 31 and 32 in the X direction, a motor drive unit 510 that drives a motor constituting the unit X-direction moving mechanism 550, and the liquid discharge head units 31 and 32 in the Y direction ( A motor driving unit 511 that drives a motor that constitutes the Y-direction scanning mechanism 552 that moves in the sub-scanning direction) is provided.

  The control unit 500 configures a motor driving unit 513 that drives a motor that configures a stage Y-direction scanning mechanism 553 that moves the stage 37 together with the lifting unit 554 in the Y direction, and a lifting unit 554 that lifts and lowers the stage 37 in the Z direction. A motor driving unit 514 for driving the motor is provided. Note that ascending / descending in the Z direction may be configured to elevate / lower the liquid discharge head units 31 and 32 as described above.

  The control unit 500 includes a motor drive unit 516 that drives a motor 555 that rotationally drives the flattening roller 34, and a maintenance drive unit 518 that drives a maintenance mechanism 556 of the liquid discharge head unit.

The control unit 500 includes a curing control unit 519 that controls ultraviolet irradiation by the UV irradiation unit 557.
The I / O 507 of the control unit 500 receives detection signals from the temperature / humidity sensor 560 that detects temperature and humidity as environmental conditions of the apparatus, and detection signals from other sensors.
An operation panel 522 for inputting and displaying information necessary for this apparatus is connected to the control unit 500.
As described above, the control unit 500 receives modeling data from the modeling data creation device 600.

Next, a manufacturing data (modeling data) creation device for creating manufacturing data and a method for creating manufacturing data (modeling data) will be described.
The modeling data creation apparatus 600 receives information of a three-dimensional model that represents a three-dimensional model to be modeled with a three-dimensional model. Based on the received information, the modeling data creating apparatus 600 appropriately sets the shape and size of the support unit, the position (arrangement) of the support unit with respect to the model unit, and the like. Furthermore, based on the information of the modeled object composed of the model part and the support part, the modeling data creation device 600 appropriately determines the shape, size (height, width, etc.), modeling position (arrangement), etc. of the support part protection wall. Set.
In addition, when the modeling data creation apparatus 600 sets the various conditions described above, conditions that serve as a reference can be input in advance by an operator or a user. In this case, the modeling data creation device 600 can automatically select a modeling condition by comparing with a condition input in advance.
Moreover, it is good for the modeling data creation apparatus 600 to have the adjustment means which an operator or a user can correct the modeling conditions which the modeling data creation apparatus set as needed.
Then, the modeling data creation device 600 adds the modeling process of the support part protection wall to the modeling process of the modeled object composed of the model part and the support part, so that both modeling processes can be performed. Set the procedure for forming the part protection wall.
This modeling procedure is converted into XY two-dimensional data, which is one layer forming the modeling layer, as described in the section << Method for creating manufacturing data of a three-dimensional model >>. Thus, the finally generated two-dimensional data becomes the manufacturing data of the three-dimensional structure.
Manufacturing data of the created three-dimensional model is input to the control unit 500 of the modeling apparatus.

<Hardware configuration of modeling data creation device>
Hereinafter, the hardware configuration of the modeling data creation apparatus that creates the modeling data described above will be described.
FIG. 8 is a block diagram illustrating an example of a hardware configuration of the modeling data creation device.
As illustrated in FIG. 8, the modeling data creation device 600 includes a CPU (Central Processing Unit) 601, a main storage device 602, an auxiliary storage device 603, an output device 604, and an input device 605. These units are connected to each other via a bus 606.
The CPU 601 is a processing device that performs various controls and calculations. The CPU 601 implements various functions by executing an OS (Operating System) and programs stored in the main storage device 602 and the like. That is, in this embodiment, the CPU 601 functions as a control unit of the modeling data generation apparatus 600 by executing a manufacturing data (modeling data) generation program.

The manufacturing data (modeling data) creation program and various databases are not necessarily stored in the main storage device 602, the auxiliary storage device 603, or the like. Manufacturing data (modeling data) creation program and various databases are stored in other information processing devices connected to the modeling data creation device 600 via the Internet, LAN (Local Area Network), WAN (Wide Area Network), etc. May be. The modeling data creation device 600 may acquire and execute manufacturing data (modeling data) creation programs and various databases from these other information processing devices.
The main storage device 602 stores various programs, and stores data necessary for executing the various programs.
The main storage device 602 includes a ROM (Reed Only Memory) and a RAM (Random Access Memory) not shown.
The ROM stores various programs such as BIOS (Basic Input / Output System).
The RAM functions as a work range that is expanded when various programs stored in the ROM are executed by the CPU 601. There is no restriction | limiting in particular as RAM, According to the objective, it can select suitably. Examples of the RAM include DRAM (Dynamic Random Access Memory) and SRAM (Static Random Access Memory).
The auxiliary storage device 603 is not particularly limited as long as various kinds of information can be stored, and can be appropriately selected according to the purpose. Examples thereof include a solid state drive and a hard disk drive. The auxiliary storage device 603 may be a portable storage device such as a CD (Compact Disc) drive, a DVD (Digital Versatile Disc) drive, or a BD (Blu-ray (registered trademark) Disc) drive.

As the output device 604, a display or the like can be used. There is no restriction | limiting in particular as a display, A well-known thing can be used suitably, For example, a liquid crystal display and an organic EL display are mentioned.
The input device 605 is not particularly limited as long as it can accept various requests to the modeling data creation device 600, and a known device can be used as appropriate, and examples thereof include a keyboard, a mouse, and a touch panel.
With the hardware configuration as described above, the processing function of the modeling data creation apparatus 600 can be realized.

<Embodiment>
The processing procedure of the preparation method of the manufacturing data of the three-dimensional molded item of this invention is shown. FIG. 9 is a flowchart illustrating an example of a processing procedure of a manufacturing data creation method in the modeling data creation device 600.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples.

<Preparation of model part forming material>
60 parts by mass of isobornyl acrylate (manufactured by Kyoei Chemical Co., Ltd.), 10 parts by mass of acryloylmorpholine (ACMO, manufactured by KJ Chemicals Co., Ltd.), and urethane acrylate (trade name: UV-1700B, manufactured by Nippon Synthetic Chemical Industry Co., Ltd., molecular weight) : 2,000) 30 parts by mass were uniformly mixed in a beaker. Thereafter, 2 parts by mass of a photopolymerization initiator (trade name: Irgacure 819, manufactured by BASF) was added and mixed evenly, and a filter (trade name: CCP-FX-C1B, manufactured by ADVANTEC, average pore size: 3 μm) was added. The model part forming material was obtained by passing through.

<Preparation of support part forming material>
40 parts by mass of acryloylmorpholine (ACMO, manufactured by KJ Chemicals), 45 parts by mass of polyoxypropylene glycol, 15 parts by mass of 1,4-butanediol, 3 parts by mass of a reaction initiator (trade name: Irgacure 819, manufactured by BASF) And 0.1 parts by mass of a polymerization inhibitor (trade name: phenothiazine, manufactured by Tokyo Chemical Industry Co., Ltd.) are uniformly mixed and passed through a filter (trade name: CCP-FX-C1B, manufactured by ADVANTEC, average pore size: 3 μm). Thus, a support part forming material was obtained.

Example 1
In the modeling apparatus for a three-dimensional modeled object shown in FIG. 1, the obtained model part forming material and support part forming material were filled in three tanks leading to an inkjet head (trade name: MH2420, manufactured by Ricoh Industry Co., Ltd.).
The modeled object shown in FIGS. 4A and 4B was modeled. 4A and 4B, reference numeral 300 denotes a model part, reference numeral 310 denotes a support part, reference numeral 320 denotes a modeling stage, and reference numeral 330 denotes a support part protection wall (hereinafter, FIGS. 5A and 5B and FIG. In FIG. 6A and FIG. 6B, the same reference numerals are assigned to the same components as those in FIG. 4A and FIG. 4B.
In FIG. 4A, the average distance of the gap is 1 mm.

<Evaluation of modeling stage contamination>
After elapse of 60 hours from the completion of modeling, the mass of the support part forming material leaked onto the modeling stage was measured by elution of the support part forming material, and evaluated according to the following evaluation criteria.
-Evaluation criteria-
A: The mass of the support portion forming material leaked on the modeling stage is less than 1 mg.
X: The mass of the support portion forming material leaked on the modeling stage is 1 mg or more.

<Evaluation of removal rate>
The model was immersed in water at 25 ° C., and the time until the support part was completely dissolved was measured.
The evaluation results of the shaped article obtained in Example 1 are shown in Table 1 below.

(Comparative Example 1)
The modeling stage contamination and removal rate were evaluated in the same manner as in Example 1 except that the modeling object (modeling object and support part only, without the support part protection wall) shown in FIGS. 5A and 5B was produced. did. The evaluation results of the shaped product obtained in Comparative Example 1 are shown in Table 1 below.

(Comparative Example 2)
6A and 6B are the same as in Example 1 except that the modeled object (modeled object in which the support part protective wall is modeled in close contact with the support part) was produced. evaluated. The evaluation results of the shaped product obtained in Comparative Example 2 are shown in Table 1 below.

  From the results of Example 1 and Comparative Example 1 and Comparative Example 2, the manufacturing method of the present invention is used to prevent contamination of the apparatus due to elution of the material forming the support part without reducing the removal rate of the support part. It was confirmed that it could be prevented.

Aspects of the present invention are as follows, for example.
<1> A manufacturing method of a three-dimensional modeled object that models a model unit and a support unit that supports the model unit,
When modeling a model consisting of the model part and the support part, the support part positioned at the outermost contour of the model is modeled by separating a support part protective wall having a predetermined height. It is a manufacturing method of the solid modeling thing to do.
<2> An average distance between the surface of the support portion that faces the support portion protection wall and the surface of the support portion protection wall that faces the support portion that is located on the outermost contour of the modeled object. It is the manufacturing method of the three-dimensional molded item as described in said <1> which is 1 mm or more apart.
<3> The three-dimensional modeled object according to any one of <1> to <2>, wherein the support part protection wall is modeled so as to surround the modeled object at a position separated from the outermost contour of the modeled object. It is a manufacturing method.
<4> The support part protection wall is formed of a bottom part and a wall part surrounding the periphery, and has a shape of a container having an open top, and is made of a material that forms the support part on the inner surface of the bottom part of the container. 3D modeling according to any one of <1> to <3>, in which a layer formed from the model portion and the support portion is formed on the layer formed from the material forming the support portion. It is a manufacturing method of a thing.
<5> The method for manufacturing a three-dimensional structure according to any one of <1> to <4>, wherein the support portion protection wall is formed of a material forming the model portion.
<6> The method for producing a three-dimensional structure according to any one of <1> to <5>, wherein the material forming the support portion is made of a material exhibiting water disintegration.
<7> From a three-dimensional model representing a three-dimensional model to be modeled, a procedure for modeling a model consisting of a model part and a support part that supports the model part, and the support located at the outermost contour of the model On the other hand, set the procedure for shaping the support part protective wall of a predetermined height apart,
This is a method for creating manufacturing data of a three-dimensional modeled object.

  According to the method for producing a three-dimensional structure according to any one of <1> to <6>, and the method for creating the production data of the three-dimensional structure according to <7>, the conventional problems are solved. The object of the present invention can be achieved.

JP 2012-111226 A JP 2012-96428 A

DESCRIPTION OF SYMBOLS 1 Model part formation material 2 Support part formation material 10 Model part 20 Support part 30 Modeling apparatus (an example of the manufacturing apparatus of a three-dimensional molded item)
31 Head unit (an example of discharge means)
32 Head unit (an example of discharge means)
33 UV irradiation machine (an example of curing means)
34 Roller 35 Carriage 36 Substrate 37 Stage 100 Three-dimensional model

Claims (7)

It is a manufacturing method of a three-dimensional modeled object which models a model part and a support part which supports the model part,
When modeling a model consisting of the model part and the support part, the support part positioned at the outermost contour of the model is modeled by separating a support part protective wall having a predetermined height. The manufacturing method of the solid modeling thing to do.   The average surface distance between the surface of the support portion that is located on the outermost contour of the model and that faces the support portion protection wall and the surface of the support portion protection wall that faces the support portion is 1 mm or more apart. The manufacturing method of the three-dimensional molded item of Claim 1.   The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 2 with which the said support part protection wall is modeled so that the said molded item may be enclosed in the position spaced apart from the outermost outline of the said molded item.   The support part protective wall is formed of a bottom part and a wall part surrounding the periphery, and has a shape of a container having an open top, and a layer made of a material forming the support part on the inner surface of the bottom part of the container. The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 3 which models and forms the molded article which consists of the said model part and the said support part on the layer which consists of the material which forms and forms the said support part.   The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 4 in which the said support part protection wall is formed with the material which forms the said model part.   The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 5 which consists of the material in which the material which forms the said support part shows water disintegration. From the three-dimensional model representing the three-dimensional model to be modeled, the procedure for modeling the model consisting of the model part and the support part that supports the model part, and the support located at the outermost contour of the model, Set the procedure to form the support part protective wall with a predetermined height apart,
A method for producing manufacturing data of a three-dimensional structure characterized by that.