JP2019157201A - Stereo model object producing process, stereo model object producing apparatus, and stereo model object producing program - Google Patents

Abstract

To provide a stereo model object producing process in which the discharge stability of the liquid for modeling a stereo model object can be enhanced, and the dimensional accuracy and excess powder removal efficiency of the stereo model object can be improved.SOLUTION: Provided is a stereo model object producing process comprising: a forming step for forming a powder layer comprising particles for modeling, a first resin, and a second resin; a first solidification step for ejecting and solidifying a first liquid capable of dissolving the first resin into a modeling region of the powder layer; and a second solidification step for ejecting and solidifying a second liquid capable of dissolving the second resin into an adjacent region adjacent to the modeling region.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method for manufacturing a three-dimensional model, a manufacturing apparatus for a three-dimensional model, and a program for manufacturing a three-dimensional model.

  In the powder additive manufacturing method, a layered object is formed by integrating the powdered material layer by layer by melting with an electromagnetic radiation source such as a laser or bonding with a binder resin, and the layered object is stacked to form a three-dimensional object. This is a method for manufacturing a product.

  As a method using an electromagnetic irradiation source, for example, an SLS (Selective Laser Sintering) method in which a powder material is melted and integrated by selectively irradiating the powder material with a laser beam to manufacture a three-dimensional model is known. ing. On the other hand, as a method using a binder resin, for example, there is known a binder jetting method in which an ink containing a binder resin is ejected and integrated with a powder material by a method such as inkjet to produce a three-dimensional model. Yes.

  Various proposals have been made to improve the quality of the three-dimensional structure manufactured by the binder jet method. For example, for the purpose of improving the dimensional accuracy by smoothing the outer surface of a three-dimensional modeled object, a manufacturing method has been proposed in which different types of thermosetting resin-containing inks are discharged to a modeling area and a non-modeling area (for example, patents). Reference 1).

  It is an object of the present invention to provide a method for manufacturing a three-dimensional structure that can increase the discharge stability of a liquid for modeling a three-dimensional structure, and can improve the dimensional accuracy and excess powder removal efficiency of the three-dimensional structure. And

  The manufacturing method of the three-dimensional molded item of the present invention as a means for solving the problem includes a forming step of forming a powder layer including particles for modeling, a first resin, and a second resin, and the first resin. A first solidifying step for discharging and solidifying a first liquid capable of dissolving the liquid to the modeling region of the powder layer; and a second liquid capable of dissolving the second resin adjacent to the modeling region. And a second solidification step for solidifying by discharging to the region.

  According to the present invention, it is possible to provide a method for manufacturing a three-dimensional structure that can increase the discharge stability of a liquid for modeling a three-dimensional structure and can improve the dimensional accuracy and excess powder removal efficiency of the three-dimensional structure. Can do.

FIG. 1 is a schematic plan view illustrating a manufacturing apparatus for a three-dimensional structure according to the first embodiment. FIG. 2 is a schematic side view of the manufacturing apparatus for the three-dimensional structure shown in FIG. FIG. 3 is a schematic cross-sectional view showing a modeling part of the three-dimensional model manufacturing apparatus shown in FIG. FIG. 4 is a block diagram illustrating a manufacturing apparatus for a three-dimensional structure according to the first embodiment. FIG. 5A is a schematic cross-sectional view illustrating the flow of the modeling operation in the first embodiment. FIG. 5B is a schematic cross-sectional view illustrating the flow of the modeling operation in the first embodiment. FIG. 5C is a schematic cross-sectional view illustrating the flow of the modeling operation in the first embodiment. FIG. 5D is a schematic cross-sectional view illustrating the flow of the modeling operation in the first embodiment. FIG. 5E is a schematic cross-sectional view illustrating the flow of the modeling operation in the first embodiment. FIG. 6 is an explanatory diagram illustrating a modeling operation according to the first embodiment. FIG. 7 is an explanatory diagram illustrating a modeling operation according to the second embodiment. FIG. 8 is an explanatory diagram illustrating a modeling operation according to the third embodiment. FIG. 9 is an explanatory diagram illustrating a modeling operation according to the fourth embodiment. FIG. 10 is an explanatory diagram illustrating a modeling operation according to the fifth embodiment. FIG. 11 is a flowchart illustrating a flow of processing for performing a modeling operation in the third embodiment.

(Manufacturing method of three-dimensional structure, manufacturing apparatus of three-dimensional structure, and manufacturing program of three-dimensional structure)
The apparatus for manufacturing a three-dimensional object of the present invention operates as an apparatus for executing the method for manufacturing a three-dimensional object of the present invention by reading and executing the manufacturing program for the three-dimensional object of the present invention. That is, the three-dimensional object manufacturing apparatus of the present invention has the three-dimensional object manufacturing program of the present invention that causes a computer to execute the same function as the method of manufacturing the three-dimensional object of the present invention.
In other words, the three-dimensional object manufacturing apparatus of the present invention is synonymous with carrying out the method of manufacturing the three-dimensional object of the present invention. Details of the manufacturing method will be clarified. Moreover, the manufacturing program of the three-dimensional molded item of this invention is implement | achieved as a manufacturing apparatus of the three-dimensional molded item of this invention by using the computer etc. as a hardware resource. For this reason, the details of the manufacturing program for the three-dimensional object of the present invention will be clarified through the description of the manufacturing apparatus for the three-dimensional object of the present invention.
In addition, the manufacturing program of the three-dimensional modeled object of the present invention is not limited to be executed by the three-dimensional modeled object manufacturing apparatus of the present invention. For example, the three-dimensional structure manufacturing program of the present invention may be executed by another computer or server, and any one of the three-dimensional structure manufacturing apparatus, other computer, and server of the present invention executes in cooperation. May be.

The manufacturing apparatus of the three-dimensional structure according to the present invention comprises a forming means for forming a powder layer containing modeling particles, a first resin and a second resin, and a first liquid capable of dissolving the first resin. A first solidifying means for discharging and solidifying the modeling layer of the body layer; a second solidifying means for discharging and solidifying a second liquid capable of dissolving the second resin to the adjacent area adjacent to the modeling area; Have.
The manufacturing apparatus of the three-dimensional modeled object of the present invention is based on the knowledge that, in the conventional binder jet technology, the modeling ink contains a resin, the viscosity becomes high and the ejection stability of the ink jet tends to be low. is there.

  The manufacturing method of the three-dimensional modeled object of the present invention is the first liquid by discharging the first liquid to the modeling area for modeling the three-dimensional modeled object and the second liquid to the peripheral area adjacent to the modeling area. , It is possible to increase the dimensional accuracy of the three-dimensional structure. In addition, for example, when a three-dimensional model is modeled with the first resin, the second resin solidified adjacent to the three-dimensional model is dissolved with the second liquid, thereby surrounding the three-dimensional model. Since the excess powder adhering to the surface can be removed at once, the excess powder removal efficiency can be improved as compared with the case of removing by applying external force. Furthermore, since the first liquid and the second liquid do not contain a resin, the viscosity can be lowered. For this reason, since the manufacturing apparatus of the three-dimensional molded item of this invention discharges the 1st liquid and 2nd liquid with low viscosity, it can improve discharge stability.

  The manufacturing apparatus of the three-dimensional molded item of this invention has a formation means, a 1st solidification means, and a 2nd solidification means, and also has another means as needed.

<Formation means>
The forming means forms a powder layer containing the modeling particles, the first resin, and the second resin.
The forming means is not particularly limited and may be appropriately selected depending on the purpose. Examples thereof include a combination of a mechanism for supplying powder and a mechanism for forming a layer while leveling the supplied powder. .

<< Formation Particles >>
There is no restriction | limiting in particular as modeling particle | grains, According to the objective, it can select suitably, For example, the particle | grains etc. which are insoluble in water and an organic solvent are mentioned.
Examples of materials that are insoluble in water and organic solvents include stainless steel, titanium, aluminum, magnetic materials, glass, and sand. These may be used individually by 1 type and may use 2 or more types together. Among these, examples of the modeling particles having ignitability include stainless steel, titanium, and aluminum.

<< first resin and second resin >>
Examples of the first resin include a resin that is soluble in water and insoluble in an organic solvent (hereinafter, sometimes referred to as “water-soluble / organic solvent-insoluble resin”).
Examples of the water-soluble / organic solvent-insoluble resin include polyvinyl alcohol (PVA), polyglycolic acid (PGA), glucose and the like.
Examples of the second resin include resins that are insoluble in water and soluble in organic solvents (hereinafter sometimes referred to as “water-insoluble / organic solvent-soluble resins”).
Examples of the water-insoluble / organic solvent-soluble resin include polymethyl methacrylate (PMMA), biphenyl, and polyvinyl acetate.
Examples of the organic solvent include acetone, ethanol, benzene, chloroform, and the like.
The first resin and the second resin may be, for example, one of which is a water-soluble / organic solvent-insoluble resin and the other of which is a water-insoluble / organic solvent-soluble resin. Therefore, the first resin is a water-soluble / organic solvent-insoluble resin, and the second resin is a water-insoluble / organic solvent-soluble resin.

  At least one of the first resin and the second resin is preferably fine particles. If at least one of the first resin and the second resin is a fine particle, the fluidity of the modeling particles is hardly hindered, so that the powder layer can be easily formed. In addition, it is possible to easily use the fine particles of at least one of the first resin and the second resin as a material for the powder layer by mixing them with one or more kinds of modeling particles. Layer material variations can be increased.

  The modeling particles are preferably covered with at least one of the first resin and the second resin. When the modeling particles are covered with at least one of the first resin and the second resin, when the modeling particles having ignitability are used, ignition is prevented by preventing the modeling particles from being exposed to the atmosphere. Can be suppressed. Further, when the modeling particles are covered with at least one of the first resin and the second resin, the modeling particles are easily adhered to each other when the liquid is discharged, and thus solidified. The mechanical strength of the green body before sintering can be improved.

  When the melting point of the modeling particles is Tm and the thermal decomposition start temperatures of the first resin and the second resin are Td1 and Td2, respectively, the following formula, Td1 <0.8 × Tm, and the following formula, Td2 < It is preferable to satisfy 0.8 × Tm. When these two formulas are satisfied, it is advantageous in that the first resin and the second resin disappear when the modeled object is heated at a temperature equal to or higher than Tm, and the purity of the modeled object is improved.

The melting point can be measured using, for example, differential scanning calorimetry.
The thermal decomposition start temperature means the lowest temperature at which thermal decomposition is possible. The thermal decomposition start temperature can be measured, for example, by differential thermothermal weight simultaneous measurement (TG-DTA).

<First solidifying means>
The first solidifying means discharges and solidifies the first liquid capable of dissolving the first resin to the modeling region of the powder layer. In addition, a modeling area | region means the area | region which models a three-dimensional molded item.
There is no restriction | limiting in particular as a 1st solidification means, According to the objective, it can select suitably, For example, the inkjet discharge head etc. are mentioned.

<< first liquid >>
The first liquid is not particularly limited as long as it can dissolve the first resin, and can be appropriately selected according to the purpose. Examples thereof include water, water containing a crosslinking agent, and water-based ink.

<Second solidification means>
The second solidifying means discharges and solidifies the second liquid capable of dissolving the second resin to the adjacent area adjacent to the modeling area. The adjacent area means a peripheral area adjacent to the modeling area.
There is no restriction | limiting in particular as a 2nd solidification means, According to the objective, it can select suitably, For example, an inkjet type discharge head etc. are mentioned similarly to a 1st solidification means.

<< second liquid >>
The second liquid is not particularly limited as long as it can dissolve the second resin, and can be appropriately selected according to the purpose. Examples thereof include ethanol, acetone, chloroform, and organic solvent-based inks. .

  It is preferable that the second resin solidified in the adjacent region has a lower binding force than the first resin solidified in the modeling region. This is advantageous in that it is easy to remove the second resin solidified in the adjacent region from the three-dimensional structure obtained by solidifying the first resin.

As the discharge timing of each liquid, when the first liquid is discharged to the peripheral portion of the modeling region and the second liquid is discharged to the peripheral portion of the adjacent region on the side adjacent to the modeling region, It is preferable to discharge the liquid and the second liquid substantially simultaneously. If the first solidifying means and the second solidifying means can discharge the first liquid and the second liquid substantially simultaneously, any of the liquids is prevented from unintentionally penetrating into the adjacent region of the powder layer. It is possible to increase the dimensional accuracy of the three-dimensional structure.
Moreover, there is no restriction | limiting in particular as substantially simultaneous, Although it can select suitably according to the objective, Within 100 milliseconds is preferable. If it is within 100 milliseconds, before one liquid penetrates into the shaping area of the powder layer, the other liquid penetrates into the adjacent area of the powder layer so that one liquid does not penetrate into the adjacent area. can do.

  In addition, although the 1st liquid containing water was discharged to the modeling area | region and the 2nd liquid containing the organic solvent was discharged to the adjacent area | region, the 2nd liquid was discharged to the modeling area | region, the 1st liquid May be discharged to adjacent areas. As a result, when the modeling area is wide, the second liquid volatilizes, so that the powder layer can be immediately stacked next, so that the modeling speed can be increased.

<Other means>
The other means is not particularly limited and can be appropriately selected according to the purpose. Examples thereof include a maintenance means for suppressing the occurrence of ejection failure in the solidifying means.

Hereinafter, although embodiment of this invention is described, this invention is not limited to these embodiment at all.
In addition, the number, position, shape, and the like of the following constituent members are not limited to the present embodiment, and can be set to a preferable number, position, shape, and the like in carrying out the present invention.

(Embodiment 1)
FIG. 1 is a schematic plan view illustrating a manufacturing apparatus for a three-dimensional structure according to the first embodiment. FIG. 2 is a schematic side view of the manufacturing apparatus for the three-dimensional structure shown in FIG. FIG. 3 is an enlarged side view showing a modeling portion of the three-dimensional model manufacturing apparatus shown in FIG. 1. FIG. 4 is a block diagram illustrating a manufacturing apparatus for a three-dimensional structure according to the first embodiment.
As shown in FIG. 1 to FIG. 4, the three-dimensional modeled manufacturing apparatus 601 includes a powder supply unit 80 that supplies powder and a modeled layer 30 that is a layered modeled product in which powders are combined. Modeling to form a three-dimensional model by discharging water-based ink 10a as the first liquid and organic solvent-based ink 10b as the second liquid to the powder layer 31 spread in layers of the part 1 and the modeling part 1 Unit 5 is provided. The water-based ink 10a and the organic solvent-based ink 10b may be collectively referred to as “the modeling liquid 10”.

  The modeling unit 1 includes a powder tank 11, a flattening roller 12 as a rotating body that is a flattening member (recoater), and the like. The flattening member may be a plate member (blade), for example, instead of the rotating body.

  The powder tank 11 includes a supply tank 21 for supplying the powder 20 and a modeling tank 22 in which a modeling layer 30 is stacked to form a three-dimensional model. The bottom of the supply tank 21 to which the powder is supplied from the powder supply unit 80 before modeling is movable up and down in the vertical direction (height direction) as the supply stage 23. Similarly, the bottom of the modeling tank 22 can be moved up and down in the vertical direction (height direction) as the modeling stage 24. A three-dimensional object in which the modeling layer 30 is laminated on the modeling stage 24 is modeled.

  The supply stage 23 is raised and lowered in the arrow Z direction (height direction) by a motor, and the modeling stage 24 is also raised and lowered by the motor 28 in the arrow Z direction.

The flattening roller 12 supplies the powder 20 supplied on the supply stage 23 of the supply tank 21 to the modeling tank 22, and is leveled and flattened by the flattening roller 12 that is a flattening member. Form.
The flattening roller 12 is disposed so as to be capable of reciprocating relative to the stage surface in the arrow Y direction along the stage surface of the modeling stage 24 (surface on which the powder 20 is loaded), and a Y direction scanning mechanism. It is moved by 552. Further, the flattening roller 12 is rotationally driven by a motor 26.

On the other hand, the modeling unit 5 includes a liquid discharge unit 50 that discharges the modeling liquid 10 to the powder layer 31 on the modeling stage 24.
The liquid discharge unit 50 includes a carriage 51 and two (or three or more) liquid discharge heads (hereinafter simply referred to as “heads”) 52 a and 52 b mounted on the carriage 51.

The carriage 51 is movably held by the guide members 54 and 55. The guide members 54 and 55 are hold | maintained so that raising / lowering is possible to the side plates 70 and 70 of both sides.
The carriage 51 is driven by an X-direction scanning mechanism 550, which will be described later, through a main scanning movement mechanism composed of a pulley and a belt. The same applies to the above).

Two heads 52a and 52b (hereinafter referred to as “heads 52” when not distinguished from each other) are each provided with two nozzle rows in which a plurality of nozzles that eject liquid are arranged. The two nozzle rows of one head 52a eject water-based ink 10a as the first liquid. The two nozzle rows of the other head 52b each discharge organic solvent-based ink 10b as the second liquid. The head configuration is not limited to this.
A plurality of tanks 60 respectively containing the water-based ink 10a and the organic solvent-based ink 10b are mounted on the tank mounting portion 56 and supplied to the heads 52a and 52b via supply tubes and the like.
A maintenance mechanism 61 that performs maintenance and recovery of the head 52 of the liquid ejection unit 50 is disposed on one side in the X direction.

  The maintenance mechanism 61 is mainly composed of a cap 62 and a wiper 63. The cap 62 is brought into close contact with the nozzle surface of the head 52 (surface on which the nozzle is formed), and the modeling liquid is sucked from the nozzle. This is for discharging the powder clogged in the nozzle and discharging the modeling liquid having a high viscosity. Thereafter, the nozzle surface is wiped (wiped) with the wiper 63 to form a meniscus of the nozzle (the inside of the nozzle is in a negative pressure state). In addition, the maintenance mechanism 61 covers the nozzle surface of the head with the cap 62 when the modeling liquid is not discharged, and prevents the powder 20 from entering the nozzle and the modeling liquid 10 from drying.

  The modeling unit 5 has a slider portion 72 movably held by a guide member 71 disposed on the base member 7, and the entire modeling unit 5 reciprocates in the Y direction (sub-scanning direction) orthogonal to the X direction. Is possible. The modeling unit 5 is reciprocally moved in the Y direction by a Y direction scanning mechanism 552 including a motor driving unit 512 described later.

  The liquid discharge unit 50 is disposed so as to be movable up and down in the arrow Z direction together with the guide members 54 and 55, and is lifted and lowered in the Z direction by a Z direction lifting mechanism 551 including a motor drive unit 511 described later.

Here, the detail of the modeling part 1 is demonstrated.
The powder tank 11 has a box shape, and includes a supply tank 21, a modeling tank 22, and a tank in which three upper surfaces of an excess powder receiving tank 25 are opened. A supply stage 23 is arranged inside the supply tank 21 and a modeling stage 24 is arranged inside the modeling tank 22 so as to be movable up and down.

  The side surface of the supply stage 23 is disposed in contact with the inner side surface of the supply tank 21. The side surface of the modeling stage 24 is disposed so as to contact the inner surface of the modeling tank 22. The upper surfaces of the supply stage 23 and the modeling stage 24 are kept horizontal.

The flattening roller 12 transports and supplies the powder 20 from the supply tank 21 to the modeling tank 22 and flattens the surface by leveling to form a powder layer 31 that is a layered powder having a predetermined thickness. .
The flattening roller 12 is a rod-shaped member that is longer than the inner dimensions of the modeling tank 22 and the supply tank 21 (that is, the width of the portion where powder is supplied or the portion where the powder is charged). It is reciprocated in the Y direction (sub-scanning direction) along the stage surface.
The flattening roller 12 moves horizontally from the outside of the supply tank 21 so as to pass above the supply tank 21 and the modeling tank 22 while being rotated by the motor 26. Thereby, the powder 20 is transported and supplied onto the modeling tank 22, and the powder layer 31 is formed by flattening the powder 20 while the flattening roller 12 passes over the modeling tank 22.

Further, as shown in FIG. 2, a powder removing plate 13 which is a powder removing member for removing the powder 20 attached to the flattening roller 12 is disposed in contact with the peripheral surface of the flattening roller 12. Has been.
The powder removing plate 13 moves together with the flattening roller 12 while in contact with the peripheral surface of the flattening roller 12. Further, the powder removing plate 13 can be arranged in the forward direction even in the counter direction when rotating in the rotation direction when the flattening roller 12 performs flattening.

  In the present embodiment, the powder tank 11 of the modeling unit 1 has two tanks of the supply tank 21 and the modeling tank 22, but the powder is supplied from the powder supply unit 80 to the modeling tank 22 only as the modeling tank 22. It is also possible to provide a structure in which the material is supplied and flattened by the flattening means.

Next, the outline | summary of the control part of the manufacturing apparatus 601 of a three-dimensional molded item is demonstrated with reference to FIG.
The control unit 500 includes a CPU 501 that controls the entire manufacturing apparatus 601 for a three-dimensional structure, a program including a program for causing the CPU 501 to execute control of a three-dimensional structure operation including control according to the present invention, and other fixed data. A main control unit 500A including a ROM 502 for storing and a RAM 503 for temporarily storing modeling data and the like is provided.

  The control unit 500 includes a non-volatile memory (NVRAM) 504 for holding data even when 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.

  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. The modeling data creation device 600 is a device that creates modeling data obtained by slicing a final shaped model into each modeling layer, and is configured by an information processing device such as a personal computer.

The control unit 500 includes an I / O 507 for taking in detection signals of various sensors.
The control unit 500 includes a head drive control unit 508 that drives and controls each head 52 of the liquid ejection unit 50.
The control unit 500 drives the motor constituting the X-direction scanning mechanism 550 that moves the carriage 51 of the liquid discharge unit 50 in the X direction (main scanning direction), and the modeling unit 5 in the Y direction (sub-scanning). The motor driving unit 512 that drives the motor that constitutes the Y-direction scanning mechanism 552 that is moved in the direction) is provided.
The control unit 500 includes a motor drive unit 511 that drives a motor that constitutes a Z-direction lifting mechanism 551 that moves (lifts) the carriage 51 of the liquid discharge unit 50 in the Z direction. In addition, raising / lowering to the arrow Z direction can also be set as the structure which raises / lowers the modeling unit 5 whole.
The control unit 500 includes a motor drive unit 513 that drives a motor 27 that raises and lowers the supply stage 23, and a motor drive unit 514 that drives a motor 28 that raises and lowers the modeling stage 24.
The control unit 500 includes a motor drive unit 515 that drives the motor 553 of the Y-direction scanning mechanism 552 that moves the flattening roller 12 and a motor drive unit 516 that drives the motor 26 that rotationally drives the flattening roller 12. .
The control unit 500 includes a supply drive unit 519 that drives the powder supply unit 80 that supplies the powder 20 to the supply tank 21 and a maintenance drive unit 518 that drives the maintenance mechanism 61 of the liquid discharge unit 50.
The control unit 500 includes a supply driving unit 519 for supplying the powder 20 from the powder supply unit 80.
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.
The modeling apparatus is configured by the modeling data creating apparatus 600 and the three-dimensional modeled manufacturing apparatus 601.

Next, the flow of modeling will be described with reference to FIGS. 5A to 5E. 5A to 5E are schematic explanatory views for explaining the flow of modeling.
It demonstrates from the state in which the 1st modeling layer 30 is formed on the modeling stage 24 of the modeling tank 22. FIG.
When the next modeling layer 30 is formed on the modeling layer 30, as shown in FIG. 5A, the supply stage 23 of the supply tank 21 is raised in the Z1 direction, and the modeling stage 24 of the modeling tank 22 is lowered in the Z2 direction. .

  At this time, the lowering distance of the modeling stage 24 is set so that the distance between the upper surface (powder layer surface) of the modeling tank 22 and the lower portion (downward tangent portion) of the flattening roller 12 is Δt. This interval Δt corresponds to the thickness of the powder layer 31 to be formed next. The interval Δt is preferably about several tens to 100 μm.

  Next, as shown in FIG. 5B, the powder 20 positioned above the upper surface level of the supply tank 21 is moved in the Y2 direction (modeling tank 22 side) while rotating the flattening roller 12 in the forward direction (arrow direction). By moving, the powder 20 is transported and supplied to the modeling tank 22 (powder supply).

  Further, as shown in FIG. 5C, the flattening roller 12 is moved in parallel with the stage surface of the modeling stage 24 of the modeling tank 22, and as shown in FIG. 5D, a predetermined thickness is formed on the modeling layer 30 of the modeling stage 24. A powder layer 31 that becomes Δt is formed (flattened). After forming the powder layer 31, the flattening roller 12 is moved in the Y1 direction and returned to the initial position as shown in FIG. 5D.

  Here, the flattening roller 12 can move while maintaining a constant distance from the upper surface level of the modeling tank 22 and the supply tank 21. Since the powder 20 is transported onto the modeling tank 22 by the flattening roller 12 while being kept constant, the powder having a uniform thickness Δt is formed on the modeling tank 22 or the already formed modeling layer 30. Layer 31 can be formed.

  Thereafter, as shown in FIG. 5E, the droplet of the modeling liquid 10 is discharged from the head 52 of the liquid discharge unit 50, and the modeling layer 30 is laminated and formed on the next powder layer 31 (modeling). Details of this modeling operation will be described later with reference to FIGS.

Next, a new modeling layer 30 is formed by repeating the above-described process of forming the powder layer 31 by powder supply and flattening and the modeling liquid discharging process by the head 52. At this time, the new modeling layer 30 and the lower modeling layer 30 are integrated to form a part of the three-dimensional modeled object.
Thereafter, the step of forming the powder layer 31 by supplying and flattening the powder and the step of discharging the modeling liquid by the head 52 are repeated as many times as necessary to complete the three-dimensional modeled object (three-dimensional modeled object).

Next, the modeling operation in the first embodiment will be described.
FIG. 6 is an explanatory diagram illustrating a modeling operation according to the first embodiment. FIG. 6 shows a state in which the powder layer 31 is formed by supplying and flattening the powder 20 as shown in FIGS. 5A to 5D. The powder 20 contains modeling particles 20c, a water-soluble / organic solvent-insoluble resin 20a as a first resin, and a water-insoluble / organic solvent-soluble resin 20b as a second resin.

  First, the head 52 discharges the aqueous ink 10 a as the first liquid to the modeling region of the powder layer 31. The water-based ink 10a contains water and does not contain an organic solvent. For this reason, the water-soluble / organic solvent-insoluble resin 20a in the modeling area where the water-based ink 10a is discharged is dissolved, and after the solvent component of the water-based ink 10a is volatilized, the dissolved water-soluble / organic solvent-insoluble resin 20a is solidified. To do.

  Next, the head 52 uses the organic solvent-based ink 10b as the second liquid as a non-modeling region corresponding to the peripheral portion of the modeling region (this non-modeling region is referred to as “adjacent region” or “non-modeling / solidification region”). To be discharged). In addition, the non-modeling region into which neither the water-based ink 10a nor the organic solvent-based ink 10b permeates may be referred to as “non-modeling / non-solidified region”. The organic solvent-based ink 10b contains an organic solvent and does not contain water. Therefore, after the organic solvent-based ink 10b is discharged, the water-insoluble / organic solvent-soluble resin 20b in the non-molded / solidified region is dissolved and the solvent component of the organic solvent-based ink 10b is volatilized, and then the dissolved water-insoluble / organic The solvent-soluble resin 20b is solidified. By discharging the organic solvent-based ink 10b to the adjacent region, the penetration of the water-based ink 10a to the non-modeling region is suppressed, so that the water-based ink 10a does not protrude from the modeling region that is a region for forming the three-dimensional modeled object, The dimensional accuracy of a three-dimensional molded item can be improved. In addition, since neither the water-based ink 10a nor the organic solvent-based ink 10b contains a resin and the viscosity of the ink discharged by the head 52 can be lowered, the discharge stability of the head 52 can be improved. .

  And the manufacturing apparatus of the three-dimensional molded item in Embodiment 1 completes the modeling operation such as supply of powder, flattening, discharge of the water-based ink 10a, and discharge of the organic solvent-based ink 10b by repeating the required number of times based on the modeling data. Let The three-dimensional modeled object modeled by the modeling operation based on the modeling data is taken out from the modeling stage and immersed in an organic solvent. Then, since the water-insoluble / organic solvent-soluble resin 20b in the non-molded / solidified region is dissolved, unnecessary excess powder is removed at once, so that the excess powder removal efficiency compared to external force application such as air blasting Can be improved.

(Embodiment 2)
In the second embodiment, the head 52 can be reciprocated in the main scanning direction in the first embodiment, water-based ink is ejected in the forward path, and organic solvent-based ink is ejected in the return path.
FIG. 7 is an explanatory diagram illustrating a modeling operation according to the second embodiment.
As shown in FIG. 7, when the head 52 moves in the forward direction, the water-based ink 10a is ejected to the modeling area, and then when the head 52 moves in the backward direction, the organic solvent-based ink 10b is not shaped and solidified. Discharge into the area. However, the time from the discharge of the water-based ink 10a to the discharge of the organic solvent-based ink 10b is set to be within 100 milliseconds. If it is within 100 milliseconds, the organic solvent-based ink 10b penetrates into the adjacent region of the powder layer 31 before the discharged aqueous ink 10a protrudes and penetrates into the non-modeling region of the powder layer 31, It is possible to prevent the aqueous ink 10a from protruding from the modeling region. Thereby, the manufacturing apparatus of the three-dimensional molded item in Embodiment 2 can improve the dimensional accuracy of the three-dimensional molded item.
In the second embodiment, as in the first embodiment, the ejection stability of the head 52 can be increased and the excess powder removal efficiency can be improved.

(Embodiment 3)
In the third embodiment, in the second embodiment, the head 52 discharges both the water-based ink 10a and the organic solvent-based ink 10b on the forward path in the main scanning direction.
FIG. 8 is an explanatory diagram illustrating a modeling operation according to the third embodiment.
As shown in FIG. 8, when the head 52 moves in the forward direction, the water-based ink 10a is discharged to the modeling region, and then the organic solvent-based ink 10b is discharged to the non-modeling / solidification region. However, the time from the discharge of the water-based ink 10a to the discharge of the organic solvent-based ink 10b is set to be within 100 milliseconds. As in the second embodiment, if the time is within 100 milliseconds, the organic solvent-based ink 10b is adjacent to the powder layer 31 before the ejected aqueous ink 10a protrudes and penetrates into the non-modeling region of the powder layer 31. By penetrating into the region, it is possible to prevent the aqueous ink 10a from protruding from the modeling region. Thereby, the manufacturing apparatus of the three-dimensional molded item in Embodiment 3 can improve the dimensional accuracy of the three-dimensional molded item.
In the third embodiment, as in the first embodiment, the ejection stability of the head 52 can be increased and the excess powder removal efficiency can be improved.

(Embodiment 4)
In the fourth embodiment, the water-based ink 10a and the organic solvent-based ink 10b are replaced in the first embodiment.
FIG. 9 is an explanatory diagram illustrating a modeling operation according to the fourth embodiment.
As shown in FIG. 9, the powder 20 includes, as in the first embodiment, the modeling particles 20 c, the water-soluble / organic solvent-insoluble resin 20 a as the first resin, and the water-insoluble as the second resin. -Organic solvent soluble resin 20b is contained.

  Unlike the first embodiment, the head 52 discharges the organic solvent-based ink 10 b to the modeling region of the powder layer 31. For this reason, the water-insoluble / organic solvent-soluble resin 20b in the modeling area where the organic solvent-based ink 10b is discharged is dissolved, and after the solvent component of the organic solvent-based ink 10b is volatilized, the dissolved water-insoluble / organic solvent-soluble is dissolved. The resin 20b is solidified. At this time, since the solvent component that volatilizes is an organic solvent, it is excellent in quick-drying, so even if the modeling area is large, the next powder layer can be immediately stacked and formed. Speed can be improved.

  Next, the head 52 discharges the water-based ink 10a to the non-modeling / solidification region. After the water-based ink 10a is discharged, the water-soluble / organic solvent-insoluble resin 20a in the non-molded / solidified region is dissolved and the solvent component of the water-based ink 10a is volatilized, and then the dissolved water-soluble / organic solvent-insoluble resin 20a is solidified. To do. By discharging the water-based ink 10a to the adjacent region, the penetration of the organic solvent-based ink 10b into the non-modeling region is suppressed, so that the organic solvent-based ink 10b protrudes from the modeling region that is a region for forming the three-dimensional modeled object. Can not be.

And the manufacturing apparatus of the three-dimensional molded item in Embodiment 4 completes the modeling operation such as supply of powder, flattening, discharge of the organic solvent ink 10b, and discharge of the water-based ink 10a by repeating the required number of times based on the modeling data. Let The three-dimensional modeled object modeled by the modeling operation based on the modeling data is taken out from the modeling stage and immersed in water. Then, as the water-soluble / organic solvent-insoluble resin 20a in the non-molded / solidified region dissolves, unnecessary excess powder is removed at once as in the first embodiment, so that external force application such as air blast is applied. Compared with, the excess powder removal efficiency can be improved.
In the fourth embodiment, the ejection stability of the head 52 can be improved as in the first embodiment.

(Embodiment 5)
In the fifth embodiment, in the first embodiment, the modeling particles 20c are coated with the water-soluble / organic solvent-insoluble resin 20a.
FIG. 10 is an explanatory diagram illustrating a modeling operation according to the fifth embodiment.
As shown in FIG. 10, the modeling operation is the same as that of the first embodiment, but the modeling particles have ignitability because the modeling particles 20 c are covered with the water-soluble / organic solvent-insoluble resin 20 a. In some cases, ignition can be suppressed by preventing the modeling particles from being exposed to the atmosphere. Further, if the modeling particles are covered with at least one of the first resin and the second resin, the molding particles 20c are easily bonded to each other when one of the liquids is discharged. The mechanical strength of the green body before sintering in the finished state can be improved.
In the fifth embodiment, as in the first embodiment, the ejection stability of the head 52 can be increased and the excess powder removal efficiency can be improved.

  Next, among the first to fifth embodiments, a three-dimensional object manufacturing program according to the present invention that causes a computer to execute the same function as the modeling operation of the three-dimensional object manufacturing method according to the third embodiment will be described. The processing by the three-dimensional structure manufacturing program of the present invention can be executed using a computer having the control unit 500 of the three-dimensional structure manufacturing apparatus 601 of the present invention.

  FIG. 11 is a flowchart illustrating a flow of processing for performing a modeling operation in the third embodiment. Here, the flow of the process for performing the modeling operation in the third embodiment will be described according to the step represented by S in the flowchart of FIG.

  In step S101, when the control unit 500 reads the modeling data received from the modeling data creation device 600, the process proceeds to S102.

  In step S102, the control unit 500 starts a modeling operation based on the modeling data, and moves each unit such as the head 52 to the initial position by each driving unit, and the process proceeds to S103.

  In step S103, the controller 500 contains the modeling particles 20c, the water-soluble / organic solvent-insoluble resin 20a as the first resin, and the water-insoluble / organic solvent-soluble resin 20b as the second resin. When the powder layer 31 is formed by the powder 20 to be processed, the process proceeds to S104.

  In step S104, when the control unit 500 determines that the ejection position of the head 52 is the modeling region based on the modeling data, the process proceeds to S107. If the controller 500 determines that the ejection position of the head 52 is not a modeling area, the process proceeds to S105.

  In step S105, when the control unit 500 determines that the ejection position of the head 52 is the non-modeling / solidified region based on the modeling data, the process proceeds to S106. If the controller 500 determines that the ejection position of the head 52 is not the non-modeling / solidification region, the process proceeds to S108.

  In step S106, when the control unit 500 causes the head 52 to eject the organic solvent-based ink 10b, the process proceeds to S108.

  In step S107, when the control unit 500 causes the head 52 to eject the water-based ink 10a, the process proceeds to S108.

  In step S108, when the control unit 500 determines that the shaping operation of the powder layer is completed, the process proceeds to S110. If the controller 500 determines that the modeling operation of the powder layer has not been completed, the process proceeds to S109.

  In step S109, when the control unit 500 moves the ejection position of the head 52, the process returns to S104.

  In step S110, if the control unit 500 determines that the modeling operation based on the modeling data is not completed, the process returns to S103. Moreover, if the control part 500 determines with the modeling operation based on modeling data having been complete | finished, this process will be complete | finished.

As described above, in the method for manufacturing a three-dimensional structure according to the present invention, first, a powder layer including the particles for modeling, the first resin, and the second resin is formed. Then, the first liquid capable of dissolving the first resin is discharged and solidified to the modeling region of the powder layer, and the second liquid capable of dissolving the second resin is discharged to the adjacent region adjacent to the modeling region. And solidify.
Thereby, in the manufacturing method of the three-dimensional modeled object of the present invention, for example, if the first liquid and the second liquid can be discharged to the powder layer, any one of the liquids unintentionally penetrates into the adjacent region of the powder layer. This can be suppressed, and the dimensional accuracy of the three-dimensional structure can be increased.
In addition, for example, when a three-dimensional model is modeled with the first resin, the second resin solidified adjacent to the three-dimensional model is dissolved with the second liquid, thereby surrounding the three-dimensional model. Since excess powder adhering to the surface can be removed at once, productivity can be improved as compared with the case of removing by applying external force.
Furthermore, since the first liquid and the second liquid do not contain a resin, the viscosity can be lowered. For this reason, since the manufacturing apparatus of the three-dimensional molded item of this invention discharges the 1st liquid and 2nd liquid with low viscosity, it can improve discharge stability.

As an aspect of this invention, it is as follows, for example.
<1> A forming step of forming a powder layer containing modeling particles, a first resin, and a second resin;
A first solidification step of discharging and solidifying a first liquid capable of dissolving the first resin to a modeling region of the powder layer;
A second solidifying step of discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
It is a manufacturing method of the three-dimensional molded item characterized by including.
<2> The method for producing a three-dimensional structure according to <1>, wherein the second resin solidified in the adjacent region has a lower binding force than the first resin solidified in the modeling region.
<3> When the first liquid is discharged to the periphery of the modeling area and the second liquid is discharged to the periphery of the adjacent area on the side adjacent to the modeling area, the first liquid is used. The method for producing a three-dimensional structure according to any one of <1> to <2>, wherein the liquid and the second liquid are discharged substantially simultaneously.
<4> In the first solidification step, the second liquid is discharged into the modeling region,
In the second solidification step, the three-dimensional structure manufacturing method according to any one of <1> to <3>, wherein the first liquid is discharged to the adjacent region.
<5> The method for producing a three-dimensional structure according to any one of <1> to <4>, wherein at least one of the first resin and the second resin is fine particles.
<6> The method for producing a three-dimensional structure according to any one of <1> to <5>, wherein the modeling particles are covered with at least one of the first resin and the second resin. .
<7> Any one of <1> to <6>, wherein the first resin is soluble in water, the second resin is insoluble in water, and the first liquid is an aqueous solution. It is a manufacturing method of the three-dimensional molded item of description.
<8> When the melting point of the modeling particles is Tm, and the thermal decomposition start temperatures of the first resin and the second resin are Td1 and Td2, respectively.
It is a manufacturing method of the three-dimensional molded item in any one of said <1> to <7> which satisfy | fills following Formula, Td1 <0.8 * Tm, and following Formula, Td2 <0.8 * Tm.
<9> Forming means for forming a powder layer containing particles for modeling, the first resin and the second resin;
A first solidifying means for discharging and solidifying a first liquid capable of dissolving the first resin to a modeling region of the powder layer;
A second solidifying means for discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
It is the manufacturing apparatus of the three-dimensional molded item characterized by having.
<10> The three-dimensional structure manufacturing apparatus according to <9>, wherein the second resin solidified in the adjacent region has a lower binding force than the first resin solidified in the modeling region.
<11> The first solidifying means discharges the first liquid to a peripheral portion of the modeling area, and the second solidifying means is arranged on the peripheral edge of the adjacent area on the side adjacent to the modeling area. When discharging the second liquid,
The three-dimensional structure according to any one of <9> to <10>, wherein the first solidifying means and the second solidifying means discharge the first liquid and the second liquid substantially simultaneously. It is a manufacturing apparatus.
<12> The second solidifying means discharges the second liquid to the modeling region,
The apparatus for manufacturing a three-dimensional structure according to any one of <9> to <11>, wherein the first solidifying unit discharges the first liquid to the adjacent region.
<13> The apparatus for producing a three-dimensional structure according to any one of <9> to <12>, wherein at least one of the first resin and the second resin is fine particles.
<14> The manufacturing apparatus for a three-dimensional structure according to any one of <9> to <13>, wherein the modeling particles are covered with at least one of the first resin and the second resin. .
<15> forming a powder layer containing the modeling particles, the first resin, and the second resin;
Discharging and solidifying the first liquid capable of dissolving the first resin to the modeling region of the powder layer;
Discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
It is a manufacturing program of the three-dimensional molded item characterized by making a computer perform a process.
<16> The manufacturing program for a three-dimensional structure according to <15>, wherein the second resin solidified in the adjacent region has a lower binding force than the first resin solidified in the modeling region.
<17> When the first liquid is discharged to the peripheral portion of the modeling region and the second liquid is discharged to the peripheral portion of the adjacent region on the side adjacent to the modeling region, the first liquid is used. The manufacturing program for a three-dimensional structure according to any one of <15> to <16>, wherein the liquid and the second liquid are discharged substantially simultaneously.
<18> The second liquid is discharged into the modeling region,
The manufacturing program for a three-dimensional structure according to any one of <15> to <17>, wherein the first liquid is discharged to the adjacent region.
<19> The three-dimensional structure manufacturing program according to any one of <15> to <18>, wherein at least one of the first resin and the second resin is fine particles.
<20> The manufacturing program for a three-dimensional structure according to any one of <15> to <19>, wherein the modeling particles are covered with at least one of the first resin and the second resin. .

  The method for producing a three-dimensional structure according to any one of <1> to <8>, the apparatus for producing a three-dimensional structure according to any one of <9> to <14>, and <20> to <20>. According to the manufacturing program for a three-dimensional structure according to any one of the above, the above-described problems can be solved and the object of the present invention can be achieved.

Japanese Patent Laying-Open No. 2015-139777

10a Water-based ink (first liquid)
10b Organic solvent-based ink (second liquid)
12 Flattening roller (part of forming means)
20 Powder 20a Water soluble / organic solvent insoluble resin (first resin)
20b Water insoluble / organic solvent soluble resin (second resin)
20c Particles for modeling 31 Powder layer 52 Head (first solidification means, second solidification means)
80 Powder supply part (part of forming means)
601 Manufacturing apparatus for three-dimensional structure

Claims (10)

A forming step of forming a powder layer containing the particles for modeling, the first resin and the second resin;
A first solidification step of discharging and solidifying a first liquid capable of dissolving the first resin to a modeling region of the powder layer;
A second solidifying step of discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
The manufacturing method of the three-dimensional molded item characterized by including.   The manufacturing method of the three-dimensional molded item according to claim 1, wherein the second resin solidified in the adjacent region has a lower binding force than the first resin solidified in the modeling region.   In the case where the first liquid is discharged to the peripheral portion of the modeling region and the second liquid is discharged to the peripheral portion of the adjacent region on the side adjacent to the modeling region, the first liquid and the The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 2 which discharges a 2nd liquid substantially simultaneously. In the first solidification step, the second liquid is discharged into the modeling region,
The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 3 which discharges a said 1st liquid to the said adjacent area | region in a said 2nd solidification process.   The method for producing a three-dimensional structure according to any one of claims 1 to 4, wherein at least one of the first resin and the second resin is fine particles.   The manufacturing method of the three-dimensional molded item according to any one of claims 1 to 5, wherein the modeling particles are covered with at least one of the first resin and the second resin.   The three-dimensional structure according to any one of claims 1 to 6, wherein the first resin is soluble in water, the second resin is insoluble in water, and the first liquid is an aqueous solution. Production method. When the melting point of the modeling particles is Tm, and the thermal decomposition start temperatures of the first resin and the second resin are Td1 and Td2, respectively.
The manufacturing method of the three-dimensional molded item in any one of Claim 1 to 7 which satisfy | fills following Formula, Td1 <0.8 * Tm, and following Formula, Td2 <0.8 * Tm. Forming means for forming a powder layer containing the particles for modeling, the first resin and the second resin;
A first solidifying means for discharging and solidifying a first liquid capable of dissolving the first resin to a modeling region of the powder layer;
A second solidifying means for discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
An apparatus for producing a three-dimensional structure, characterized by comprising: Forming a powder layer containing the particles for modeling, the first resin and the second resin;
Discharging and solidifying the first liquid capable of dissolving the first resin to the modeling region of the powder layer;
Discharging and solidifying a second liquid capable of dissolving the second resin to an adjacent region adjacent to the modeling region;
A manufacturing program for a three-dimensional structure, which causes a computer to execute processing.