JP2020157754A - Manufacturing apparatus of solid molded matter, manufacturing method of solid molded matter, and material set for solid molding - Google Patents

Abstract

To provide a manufacturing apparatus of a solid molded matter, which can improve molding accuracy of the solid molded matter, by suppressing deformation of the solid molded matter that is molded by heating resin particles.SOLUTION: A manufacturing apparatus of a solid molded matter comprising: layer forming means for forming a particle layer containing resin particles; first discharging means for discharging a model material capable of absorbing energy to the particle layer to form a model region; second discharging means for discharging a support material to the particle layer to form a support region; and energy imparting means for imparting the energy to the model region, in which when the energy is imparted to the model region, the resin particles in the model region, and, the resin particles in the model region and the resin particles in the support region adjacent to the model region are fused together.SELECTED DRAWING: Figure 23

Description

The present invention relates to an apparatus for manufacturing a three-dimensional model, a method for manufacturing a three-dimensional model, and a material set for three-dimensional modeling.

Since it is possible to form a high-strength three-dimensional model, it is possible to use a device for modeling a three-dimensional model by repeatedly laminating a modeling layer (layered model) formed by solidifying a particle layer (powder layer) containing resin particles. Interest is growing. Examples of devices for forming a three-dimensional model by repeatedly laminating a modeling layer in which a particle layer is solidified include an HSS (High Speed Sintering) device, an SLS (Selective Laser Sintering) device, and a BJ (Binder Jetting). The type of device is known.

Among these, the HSS type device has attracted particular attention because it can reduce the cost (price) of the device itself and can form a three-dimensional model in a short time.
In the HSS system device, for example, a light absorbing ink containing carbon black or the like is ejected to a predetermined position of the particle layer using an inkjet head, and then the particle layer is heated by a light source such as a halogen lamp to heat the particle layer. The shaping layer is formed by solidifying the predetermined position of. Then, in the HSS type device, the three-dimensional modeled object is modeled by repeating the modeling of the modeling layer and laminating the modeling layers.

Regarding the HSS type device, the detail ink (patenting agent) is discharged around the region to be the modeling layer to suppress the diffusion of heat, thereby improving the removability of the resin particles existing around the modeling layer. A technique has been proposed (see, for example, Patent Document 1).
Further, in the BJ type device, for the purpose of improving the flatness of the three-dimensional model, the three-dimensional object is placed below the region of the particle layer (powder layer) to be the three-dimensional object via the unsolidified particle layer. A technique for forming a sacrificial model that can be separated from a model is known (see, for example, Patent Document 2).

An object of the present invention is to provide a three-dimensional model manufacturing apparatus capable of suppressing deformation of a three-dimensional model formed by heating resin particles and improving the modeling accuracy of the three-dimensional model.

The apparatus for manufacturing a three-dimensional object of the present invention as a means for solving the above problems is
A layer forming means for forming a particle layer containing resin particles,
A first ejection means for forming a model region by ejecting a model material capable of absorbing energy into a particle layer,
A second ejection means that ejects a support material into the particle layer to form a support region, and
It is equipped with an energy applying means for applying energy to the model area.
By applying energy to the model region, the resin particles in the model region and the resin particles in the model region and the resin particles in the support region in contact with the model region are fused to each other.

According to the present invention, it is possible to provide a three-dimensional model manufacturing apparatus capable of suppressing deformation of a three-dimensional model formed by heating resin particles and improving the modeling accuracy of the three-dimensional model.

FIG. 1 is a schematic side view showing a modeling layer and a region where detail ink is ejected in an example of the prior art. FIG. 2 is a schematic side view showing a modeling layer and a sacrificial model in another example of the prior art. FIG. 3 is a schematic side view showing an example of a model unit and a support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 4 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 5 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 6 is a schematic side view showing an example of an end portion of the model portion in the prior art. FIG. 7 is a schematic side view showing an example of an end portion of a model portion in the three-dimensional model manufacturing apparatus of the present invention. FIG. 8 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 9 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 10 is a schematic plan view of an embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 11 is a schematic side view of an embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 12 is a schematic side view showing a modeling portion in one embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 13 is a block diagram showing an example of the configuration of the control unit in one embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 14A is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 14B is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 14C is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 14D is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 14E is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 14F is a schematic view showing an example of the flow of modeling of a three-dimensional modeled object. FIG. 15 is an explanatory diagram showing an example of a flow when forming a support region. FIG. 16 is an explanatory diagram showing an example of a flow when forming a model region and a model portion. FIG. 17 is an explanatory diagram showing an example of a flow when removing the support portion from the three-dimensional modeled object. FIG. 18 is a diagram showing an example of a support portion formed by using the solvent volatilization method. FIG. 19 is a diagram showing an example of a support portion formed by using a heat curing method. FIG. 20 is an explanatory diagram showing an example of a flow when resin particles are fused by using a plurality of light irradiation means. FIG. 21 is a diagram showing an example of the relationship between the light emitted by the first light irradiation unit and the light emitted by the second light irradiation unit. FIG. 22 is a flowchart showing an example of the flow of processing for performing the modeling operation. FIG. 23 is a photograph of a cross section of the interface between the model portion and the support portion. FIG. 24 is a schematic side view showing an example of a model portion and a support portion in the three-dimensional model shown in FIG. FIG. 25 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention. FIG. 26 is an explanatory diagram showing an example of a flow when forming a model region and a model portion in one particle layer. FIG. 27 is a schematic side view showing an example of the structure of the carriage in the three-dimensional model manufacturing apparatus. FIG. 28 is a schematic top view showing an example of a carriage in a three-dimensional model manufacturing apparatus. FIG. 29 is a schematic top view showing another example of the carriage in the three-dimensional object manufacturing apparatus. FIG. 30 is a schematic top view showing another example of the carriage in the three-dimensional object manufacturing apparatus.

(Manufacturing equipment for 3D objects, manufacturing method for 3D objects)
The apparatus for producing a three-dimensional model of the present invention includes a layer forming means for forming a particle layer containing resin particles and a first discharging means for forming a model region by discharging a model material capable of absorbing energy into the particle layer. It has a second discharging means for forming a support region by discharging a support material into the particle layer, an energy applying means for applying energy to the model region, and further has other means as needed.
The method for producing a three-dimensional model of the present invention includes a layer forming step of forming a particle layer containing resin particles, a model region forming step of discharging a model material capable of absorbing energy into the particle layer, and forming a model region. A support region forming process in which a support material is discharged to the particle layer to form a support region, and a support region in contact with the resin particles in the model region and the resin particles in the model region and the model region by applying energy to the model region. Including an energy applying step of fusing the resin particles in the above, and further including other steps as necessary.

The method for producing a three-dimensional model of the present invention can be suitably performed by the apparatus for producing a three-dimensional model of the present invention, the layer forming step can be preferably performed by the layer forming means, and the model region forming step is the first. The support region forming step can be preferably performed by the second discharging means, the energy applying step can be preferably performed by the energy applying means, and the other steps can be performed by the other discharging means. It can be done by means.

That is, the apparatus for manufacturing a three-dimensional model of the present invention is synonymous with implementing the method for manufacturing a three-dimensional model of the present invention. Therefore, the details of the method for manufacturing the three-dimensional model of the present invention will be clarified through the description of the device for manufacturing the three-dimensional model of the present invention.

Further, in the three-dimensional model manufacturing apparatus of the present invention, in the conventional three-dimensional model modeling device, when the resin particles are heated to form the three-dimensional model, the three-dimensional model is deformed. This is based on the finding that the modeling accuracy of a three-dimensional model may decrease.

In the prior art, when a particle layer heated to a predetermined preheating temperature is newly formed (recoated) for the purpose of suppressing deformation such as warpage in a three-dimensional model, the preheating temperature is set to resin particles. It may be controlled to a temperature (ΔT) between the recrystallization temperature and the melting temperature of. In this case, when the particle layer is heated to form the modeling layer, the resin particles in the region where the model material (for example, light absorbing ink, light absorbing liquid composition) is discharged and becomes the modeling layer becomes equal to or higher than the melting temperature. Melt. The melted resin particles do not solidify (crystallize) because they do not fall below the crystallization temperature when the three-dimensional model is being modeled. For this reason, in the prior art, after the lamination of all the modeling layers is completed, the modeling layers are slowly cooled to solidify the resin particles to produce a three-dimensional model.

However, in the above-mentioned conventional three-dimensional model manufacturing apparatus, the three-dimensional model is formed due to uneven temperature in the model layer (the temperature differs depending on the position in the model layer) when the model layer is slowly cooled. Deformation such as warpage may occur.
Furthermore, in the above-mentioned conventional technique, there is a limit to the upper limit of the preheating temperature of the particle layer due to the limitation due to the heat resistance of the resin particles and the inkjet head, which have no clear difference between the recrystallization temperature and the melting temperature. There is a problem that it is difficult to use resin particles having a high melting temperature. For this reason, there is a problem that resin particles formed of super engineering plastic (super engineering plastic), amorphous resin, or the like cannot be used in the modeling apparatus for a three-dimensional model of the prior art.

In the invention described in Patent Document 1, which is an example of the prior art, detail ink (detailing agent) is ejected around a region to be a modeling layer for the purpose of improving the removability of resin particles existing around the modeling layer. Then, the diffusion of heat is suppressed.
Here, FIG. 1 is a schematic side view showing a modeling layer and a region where detail ink is ejected in an example of the prior art. The detail ink in Patent Document 1 is an aqueous liquid, and the region 33 in which the detail ink is ejected in the particle layer does not solidify. Therefore, it is considered that the technique of Patent Document 1 cannot suppress the deformation of the three-dimensional modeled object even if the detail ink is ejected around the modeling layer 30 as shown in FIG.

Further, in the invention described in Patent Document 2, which is another example of the prior art, in order to improve the flatness of the three-dimensional model, the unsolidified particle layer is below the region of the particle layer that becomes the three-dimensional model. A sacrificial model that can be separated from the three-dimensional model is formed through.
FIG. 2 is a schematic side view showing a modeling layer and a sacrificial model in another example of the prior art. In the invention of Patent Document 2, for the purpose of suppressing the adhesion or aggregation of resin particles around the modeling layer 30, for example, as shown in FIG. 2, the sacrificial model 35 is provided below the region to be a three-dimensional model. Form. Since the sacrificial model 35 in Patent Document 2 is formed at a position through the particle layer 31 which is not solidified (the modeling liquid is not discharged) with respect to the three-dimensional model, the model layer forming the three-dimensional model is formed. Not in contact with. Therefore, it is considered that the sacrificial model 35 in the technique of Patent Document 2 cannot suppress the deformation of the three-dimensional model.

Here, in the three-dimensional model manufacturing apparatus of the present invention, a model material capable of absorbing energy is discharged to form a model region, and a support material is discharged to form a support region. Then, in the three-dimensional model manufacturing apparatus of the present invention, energy is applied to the model region, so that the resin particles in the model region and the resin particles in the model region and the resin particles in the support region in contact with the model region are in contact with each other. They are fused together.
By doing so, the manufacturing apparatus for the three-dimensional model of the present invention has at least a part of a model area as a model part for forming the three-dimensional model and a support area as a support part for maintaining the shape of the model part. Can be fused. In the three-dimensional model manufacturing apparatus of the present invention, the supporting force of the support portion with respect to the model portion can be improved by fusing at least a part of the model region and the support region.

FIG. 3 is a schematic side view showing an example of a model unit and a support unit in the three-dimensional model manufacturing apparatus of the present invention. In the example shown in FIG. 3, the support portion 200 is fused to the lower surface of the model portion 30. As shown in FIG. 3, in an example of the three-dimensional model manufacturing apparatus of the present invention, since the model portion and the support portion are fused, the model portion is deformed by the supporting force of the support portion (for example, the model portion). Since the warp of the object is suppressed, the modeling accuracy of the three-dimensional model can be improved.
That is, in the three-dimensional model manufacturing apparatus of the present invention, by fusing at least a part of the model region and the support region, deformation of the three-dimensional model formed by heating the resin particles is suppressed, and the three-dimensional model is formed. The modeling accuracy of objects can be improved.

<Layer forming means, layer forming process>
The layer forming means is a means for forming a particle layer containing resin particles.
The layer forming step is a step of forming a particle layer containing resin particles.
The layer forming means is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a combination of a mechanism for supplying particles and a mechanism for forming a particle layer while leveling the supplied particles. Be done. The details of the layer forming means will be described later.

<< Resin particles >>
The resin particles mean particles containing a resin component. In the following, the resin particles may be referred to as "resin powder" or "resin powder". The resin particles may contain other components in addition to the resin component, if necessary.
The resin component is not particularly limited and may be appropriately selected depending on the intended purpose, but a thermoplastic resin is preferable.

-Thermoplastic resin-
Thermoplastic resin means a resin that plasticizes and melts when heat is applied.
The thermoplastic resin is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include crystalline resin, non-crystalline resin and liquid crystal resin. As the thermoplastic resin, a crystalline resin is preferable. Further, as the thermoplastic resin, a resin having a large difference between the melting start temperature and the recrystallization temperature at the time of cooling is preferable.
The crystalline resin is a resin in which a melting point peak is detected in a measurement based on ISO3146 (plastic transition temperature measuring method, JIS K7121).

Examples of the thermoplastic resin include polyolefin, polyamide, polyester, polyether, polyphenylene sulfide, polyacetal (POM: Polyoxymethylene), polyimide, fluororesin and the like. These may be used alone or in combination of two or more.

Examples of the polyolefin include polyethylene (PE) and polypropylene (PP).

Examples of the polyamide include polyamide 410 (PA410), polyamide 6 (PA6), polyamide 66 (PA66), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 11 (PA11), and polyamide 12 (PA12); Examples thereof include semi-aromatic polyamides such as polyamide 4T (PA4T), polyamide MXD6 (PAMXD6), polyamide 6T (PA6T), polyamide 9T (PA9T), and polyamide 10T (PA10T).

Examples of the polyester include polyethylene terephthalate (PET), polybutadiene terephthalate (PBT), polylactic acid (PLA) and the like. Among these, those having an aromatic component containing terephthalic acid or isophthalic acid as a part are preferable in terms of imparting heat resistance.

Examples of the polyether include polyaryl ketone and polyether sulfone.
Examples of the polyarylketone include polyetheretherketone (PEEK), polyetherketone (PEK), polyetherketone ketone (PEKK), polyaryletherketone (PAEK), polyetheretherketone ketone (PEEKK), and polyether. Examples thereof include ketone ether ketone ketone (PEKEKK).

The thermoplastic resin may have two melting point peaks, for example, PA9T. A thermoplastic resin having two melting point peaks melts completely when the temperature becomes higher than the melting point peak on the high temperature side.

Further, polyphthalamide, polyphenylene sulfide, liquid crystal polymer, polysulfone, polyether sulfone, polyetherimide, polyamideimide, polyether ether ketone, polytetrafluoroethylene and the like are referred to as "super engineering plastics".
The thermoplastic resin is preferably at least one selected from super engineering plastics. When the thermoplastic resin is a super engineering plastic, the tensile strength, heat resistance, chemical resistance, and flame retardancy of the three-dimensional model to be modeled can be improved, and the three-dimensional model can be used for industrial purposes. It is advantageous in that.

The shape of the resin particles is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include shapes such as a cylinder, a polygonal prism, and a sphere. Among these, a cylindrical body is preferable.

The columnar body is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a true columnar body and an elliptical columnar body. Among these, a true cylinder is preferable.
The columnar body includes a substantially cylindrical body. Here, the substantially circle means that the ratio of the major axis to the minor axis (major axis / minor axis) is 1 or more and 10 or less. Further, the circular portion of the cylinder may be partially missing.
The polygonal prism is not particularly limited as in the case of the cylinder, and can be appropriately selected depending on the intended purpose, and a part of the polygonal portion of the polygonal prism may be missing.
As with the cylindrical body, the sphere is not particularly limited and may be appropriately selected depending on the intended purpose, and a part of the sphere may be missing.

The diameter of the circular portion of the cylindrical body is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 5 μm or more and 200 μm or less. When the circular portion of the cylinder is elliptical, the diameter means the major axis.
The length of one side of the polygonal portion of the polygonal prism is not particularly limited and can be appropriately selected depending on the purpose, but the diameter of the smallest circle (minimum inclusion circle) including all the polygonal portions. Is preferably 5 μm or more and 200 μm or less.
The diameter of the sphere is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 5 μm or more and 200 μm or less.

The height of the cylinder, that is, the distance between the two opposing circular portions (distance between the upper surface and the bottom surface) is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 1 μm or more and 200 μm or less.
The height of the polygonal prism, that is, the distance between the two opposing polygonal portions (distance between the top surface and the bottom surface) is not particularly limited as in the height of the cylinder body, and can be appropriately selected depending on the purpose. However, it is preferably 1 μm or more and 200 μm or less.

The areas of the two opposing circular portions (top and bottom) of the cylinder may be different from each other. However, as the ratio (r2 / r1) of the diameter r2 of the circular portion having the larger area to the diameter r1 of the circular portion having the smaller area, the bulk density can be increased when there is no difference in the areas of the two circular portions. In terms of possible, 1.5 or less is preferable, and 1.1 or less is more preferable.
The areas of the two opposing polygonal portions (top and bottom) in the polygonal prism may be different from each other. However, as the ratio (S2 / S1) of the larger area (S2) of the polygonal portion to the smaller area (S1) of the polygonal portion, the bulk density should be the same if there is no difference in the areas of the two polygonal portions. It is preferably close to 1 in that it can be increased.
For example, when modeling a three-dimensional model using an HSS-type three-dimensional model manufacturing device, the accuracy of the model or model can be improved by increasing the bulk density of the resin particles.

It is preferable that the resin particles of a column such as a cylinder or a polygonal column do not have vertices in order to increase the bulk density. The apex means a corner portion existing in the pillar body.

<< Particle layer >>
The particle layer means a layer containing resin particles. In the following, the particle layer may be referred to as a "powder layer" or a "powder layer".
The average thickness of the particle layer is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 10 μm or more and 100 μm or less.

When the layer forming means forms the particle layer, it is preferable to preheat the resin particles so that the temperature of the resin particles becomes a desired preheating temperature. That is, in the method for producing a three-dimensional model of the present invention, it is preferable to further include a preheating step of preheating the resin particles so that the temperature of the resin particles becomes a desired preheating temperature. By doing so, even when the energy applied to the particle layer by the energy applying means is small, the particle layer can be heated so as to have a temperature at which the resin particles can be fused to each other.

The preheating temperature is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably a temperature between the recrystallization temperature and the melting temperature of the resin particles. Since the preheating temperature is a temperature between the recrystallization temperature and the melting temperature of the resin particles, the fluidity of the resin particles when forming the particle layer is maintained, and deformation such as warpage in the formed three-dimensional model is prevented. It can be suppressed.

The preheating means for performing the preheating step is not particularly limited and may be appropriately selected depending on the intended purpose. For example, a known heater, heating lamp, heating roller or the like can be used.

<First discharge means, model area forming process>
The first ejection means is a means for forming a model region by ejecting a model material capable of absorbing energy into the particle layer.
The model region forming step is a step of forming a model region by discharging a model material capable of absorbing energy into the particle layer.

<Second discharge means, support area forming process>
The second ejection means is a means for ejecting the support material into the particle layer to form a support region.
The support region forming step is a step of discharging the support material into the particle layer to form the support region.

The model portion forming step can be preferably performed by the first discharging means, and the support region forming means can be preferably performed by the second discharging means.
Here, the first discharge means and the second discharge means may be realized as one discharge means or as separate discharge means. When the first discharge means and the second discharge means are realized by one discharge means, the discharge means functions as the first discharge means when the model material is discharged, and when the support material is discharged. Functions as a second discharge means. In the following, when the first discharge means and the second discharge means are not distinguished, the first discharge means and the second discharge means may be collectively referred to as "discharge means".
The ejection means is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include an inkjet ejection head.

Further, the number of discharge means included in the three-dimensional model manufacturing apparatus is not particularly limited and can be appropriately selected depending on the purpose.

<< Model area >>
The model region is a region formed by discharging the model material capable of absorbing energy into the particle layer by the first discharging means. The model area can be formed based on the three-dimensional data in which the three-dimensional model to be manufactured (modeled) is represented by the three-dimensional model. For example, the three-dimensional data is sliced at predetermined intervals. It may be.
The formed model region is heated by applying energy by the energy applying means, so that the resin particles in the model region are fused to each other to form a model portion which is a part of the three-dimensional model. In other words, since the formed model region can efficiently absorb energy by the discharged model material, the temperature becomes higher than the melting point of the resin particles when energy is applied by the energy applying means, and the resin The particles fuse to each other and solidify.

Here, fusion of resin particles means that the resin particles are heated to a temperature equal to or higher than the melting point, so that the resin particles are solidified as one when the temperature becomes lower than the melting point of the resin particles. Means to do. Therefore, in the region where the resin particles are fused to each other, at least a part of the boundary (grain boundary) between the resin particles disappears.

<<< Model material >>
The model material is not particularly limited as long as it can absorb energy, and can be appropriately selected depending on the intended purpose. For example, a liquid composition containing a black pigment such as carbon black, a liquid composition containing a pigment, or a metal. Examples thereof include a liquid composition containing fine particles. Further, as the liquid composition, one that can be ejected using an inkjet head is preferable, and for example, ink or the like can be used.
Among these, as the model material, when the energy applying means is a light irradiating means, it is preferable that the model material can generate heat by absorbing the light irradiated by the light irradiating means, for example, the above-mentioned carbon black or the like. A liquid composition containing a black pigment (eg, black ink) is preferred. Since the model material is a liquid composition containing a black pigment, when the energy applying means is a light irradiating means, the light irradiated by the light irradiating means can be efficiently absorbed to generate heat, and the energy can be generated in the model region. Fusion of resin particles can be easily performed.

<< Support area >>
The support region is a region formed by discharging the support material by the second discharging means. The support region is, for example, a support portion that maintains the shape of the model portion by solidifying the discharged support material and adhering the resin particles to each other.
As will be described later, in the present invention, the resin particles in the model region and the resin particles in the support region are fused. That is, in the present invention, since at least a part of the model area and the support area is fused, at least a part of the model part where the model area is solidified and the support part where the support area is solidified are fused. There is. By doing so, in the three-dimensional model manufacturing apparatus of the present invention, the supporting force of the support portion with respect to the model portion can be improved. In the present invention, the model region and the support region need only be fused at a ratio that does not hinder the effect of the present invention, and all the resin particles existing at the interface between the model region and the support region are fused. You don't have to.

The position and shape of the support area are not particularly limited as long as they are in contact with at least a part of the model area, and can be appropriately selected depending on the purpose. In the following, a preferable example of the support area will be described.

When the layer forming means forms the second particle layer on the first particle layer, the first discharging means comes into contact with the planned portion to be the model region in the second particle layer. It is preferable to form a support region in the particle layer of. That is, it is preferable to form the support region so that the second discharge means is in contact with the lower side of the model region.
Here, the planned portion to be the model part in the second particle layer is specified in advance when forming the first particle layer, for example, based on the three-dimensional data representing the three-dimensional model by the three-dimensional model. Can be done. In this case, when the model material is discharged to the planned portion specified in advance in the second particle layer to form the model region, the support region in the first particle layer and the model region in the second particle layer come into contact with each other. It will be. By fusing the model region and the support region in this way, deformation of the model portion (for example, warpage of the model portion) can be suppressed by the supporting force of the support portion where the support region is solidified.
As a more specific example of the above-mentioned form, for example, in the case of manufacturing a rectangular parallelepiped three-dimensional model as shown in FIG. 3, the support portion 200 may be fused to the lower surface of the model portion 30. .. By fusing the support portion 200 to the lower surface of the model portion 30 in this way, the warp of the three-dimensional model can be suppressed more effectively.

Further, when the layer forming means forms the second particle layer on the first particle layer, the second ejection means is a region in the second particle layer in contact with the model region in the first particle layer. It is also preferable to form a support region. That is, it is preferable to form the support region so that the second discharge means is in contact with the upper side of the model region. By doing so, it is possible to suppress the deformation of the three-dimensional modeled object when the three-dimensional modeled object is cooled after being modeled.
As a more specific example of the above-mentioned form, for example, in the case of manufacturing a rectangular parallelepiped three-dimensional model as shown in FIG. 4, the support portion 200 may be fused to the upper surface of the model portion 30. ..

Further, it is also preferable that the model region formed by the first ejection means and the support region formed by the second ejection means are formed in one particle layer. That is, it is preferable to form the support region so that the second discharge means is in contact with the side surface of the model region.
As a more specific example of the above-mentioned form, for example, in the case of manufacturing a rectangular parallelepiped three-dimensional model as shown in FIG. 5, the support portion 200 may be fused to the side surface of the model portion 30. .. By doing so, it is possible to suppress the warp of the three-dimensional model.

Further, by forming the support region so as to be in contact with the side surface of the model region, it is possible to suppress the swelling of the end portion (edge) in the model portion.
For example, as shown in FIG. 6, when the support region is not formed on the side surface of the model region 101, when the particle layer is heated by the energy applying means, only the model region 101 discharged with the model material 10 m is melted and has a high density. To become. Therefore, when the support region is not provided on the side surface of the model region 101, a meniscus made of a liquid melted resin in the model portion is formed at the boundary between the model region 101 and the region (particle region) that is not the model region, and the model The surface may be formed so that the ends of the portions are raised. The swelling of the end portion of this model portion becomes particularly noticeable when modeling a three-dimensional model by the HSS method.
On the other hand, when the support region 201 is formed on the side surface of the model region 101 as shown in FIG. 7, in one embodiment, as shown in the central portion of FIG. 7, the support region 201 is supported before heating by the energy applying means. When the region 201 solidifies, the support region 201 (or the support portion 200) is densified (compressed) by the liquid cross-linking force. At this time, as shown in the right part of FIG. 7, since the end part of the model part is also compressed with the compression of the support part 200, the swelling of the end part in the model part is increased as compared with the example shown in FIG. Can be suppressed.

Further, it is preferable that the second discharging means forms a support region so that the support portion is formed on the entire surface of the three-dimensional model formed by the model portion. By doing so, it is possible to more reliably suppress deformation such as warpage of the three-dimensional modeled object when the three-dimensional modeled object is cooled after being modeled.
As a more specific example of the above-mentioned form, for example, in the case of manufacturing a rectangular parallelepiped three-dimensional model as shown in FIG. 8, the support portion 200 is fused to the entire surface of the model portion 30. Be done.

In addition, it is preferable that the support region is formed so that the second discharge means is in contact with at least a part of the region near the outer edge in the model region. In other words, it is preferable to form a support region (part) so as to be in contact with the end portion of the three-dimensional model formed by the model portion. By doing so, it is possible to effectively suppress the warp of the three-dimensional model while suppressing the amount of the support material used.
As a more specific example of the above form, for example, in the case of manufacturing a rectangular parallelepiped three-dimensional model as shown in FIG. 9, the support portion 200 is fused to the bottom end side of the model portion 30. Can be mentioned.

<<< Support material >>
The support material is not particularly limited and may be appropriately selected depending on the purpose. As the support material, a material capable of adhering resin particles to each other is preferable.
Here, adhering the resin particles to each other means that the resin particles are solidified (fixed) by solidifying the support material discharged by the discharging means. Therefore, in the region (support portion) where the resin particles are adhered to each other, a boundary (grain boundary) between the resin particles exists.

Further, when the discharged support material is solidified and the resin particles are adhered to each other, the solidification method of the support material is not particularly limited and can be appropriately selected depending on the purpose. For example, a solvent volatilization method or heating. Examples include a curing method, an ultraviolet curing method, and a curing agent mixing method. Among these, the solvent volatilization method and the heat curing method are preferable.

[Solvent volatilization method]
The solvent volatilization method is a method in which a support material containing at least an adhesive component for adhering resin particles to each other and a solvent is used, and a part of the support material (for example, a solvent) is volatilized to solidify the support material. In other words, in the solvent volatilization method, a support portion is formed by volatilizing and solidifying a part of the support material discharged by the second discharge means.
The method for volatilizing the solvent of the support material is not particularly limited and may be appropriately selected depending on the purpose. For example, the support material is heated by preheating the resin particles or applying energy by an energy applying means. Can be mentioned. As described above, in the solvent volatilization method, the support material can be solidified by an energy applying means or the like without using a special means for solidifying the support material, so that the structure of the manufacturing apparatus for the three-dimensional model is complicated. Can be prevented.

The support material in the solvent volatilization method contains an adhesive component for adhering resin particles to each other and a solvent, preferably contains an energy absorber, and further contains other components as necessary.
The adhesive component is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include soluble polymers, aqueous colloids, and inorganic solutes. Examples of the soluble polymer include a water-soluble polymer (water-soluble polymer) and an oil-soluble polymer (oil-soluble polymer).
The solvent is not particularly limited as long as it can dissolve or disperse the adhesive component, and can be appropriately selected depending on the intended purpose. Examples thereof include water and organic solvents.

The energy absorbing agent is not particularly limited as long as the energy applying means can absorb the energy applied to the particle layer, and can be appropriately selected depending on the intended purpose. Examples thereof include black pigments such as carbon black. .. Since the support material in the solvent volatilization method contains a black pigment, when the energy applying means applies energy to the particle layer, the support material absorbs the energy and generates heat, so that the volatilization of the solvent is promoted, which makes it easier. The support material solidifies.
The content of the energy absorber contained in the support material in the solvent volatilization method is such that the temperature of the resin particles in the support region does not exceed the melting point when the energy applying means applies energy to the particle layer. preferable. By doing so, it is possible to prevent deterioration of the removability of the support portion due to fusion of the resin particles in the support region.

The other components of the support material in the solvent volatilization method are not particularly limited and may be appropriately selected depending on the intended purpose. For example, a colorant, a dispersion stabilizer, a surfactant, a penetration accelerator, a moisturizer, and a fungicide. Examples include mold agents, preservatives, antioxidants, pH regulators, thickeners, fillers, anti-aggregation agents, antifoaming agents and the like.
As described above, since the support material in the solvent volatilization method does not necessarily contain a reactive compound, it is excellent in storage stability and discharge stability when discharged by the discharge means.

Further, as the adhesive component of the support material in the solvent volatilization method, it is preferable that at least one of the melting point and the softening point is higher than the preheating temperature of the resin particles. By doing so, it is possible to prevent the support material after solidification from being melted or softened by the heat applied from the resin particles, so that the strength of the support portion can be improved and the support portion can be supported by the model portion. The power can be improved.
Here, the softening point means the temperature at which a substance such as a resin softens as the temperature rises and begins to deform. Normally, when the temperature of a substance is raised, the temperature at which the substance becomes completely liquid is called the melting point, but substances such as resins gradually soften to a molten state without showing a clear melting point, and are in a clear state. Since it is difficult to identify the change, it is sometimes called the softening point to distinguish it from the melting point.
The softening point of the adhesive component in the support material can be, for example, a value measured by the Vicat softening temperature A50 method (JIS K 7206: 1999).

In addition, the solvent of the support material in the solvent volatilization method preferably has a boiling point lower than the preheating temperature of the resin particles. By doing so, when the resin particles are preheated, the solvent of the support material discharged by the second discharge means can be volatilized by the heat applied from the resin particles, so that the support material can be more easily solidified. The resin particles can be adhered to each other to form a support portion. If the support portion can be easily formed in a short time, the productivity of the three-dimensional model manufacturing apparatus can be improved.

Further, the support material in the solvent volatilization method satisfies the above two conditions, that is, at least one of the melting point and the softening point of the adhesive component is higher than the preheating temperature of the resin particles, and the boiling point of the solvent is the resin particles. It is more preferable that the temperature is lower than the preheating temperature of. By doing so, it is possible to improve the bearing capacity of the support portion with respect to the model portion, and it is possible to easily form the support portion in a short time, and it is possible to improve the productivity of the manufacturing apparatus for the three-dimensional model.

[Heat curing method]
The heat curing method uses a support material containing at least a reactive compound and a curing agent, and by heating the support material, the curing agent is activated to cause a polymerization reaction in the reactive compound to support the reaction. This is a method of solidifying the material. In other words, in the heat-curing method, the support material discharged by the second discharging means is heated to cause a polymerization reaction and is cured to form a support portion.
The method of heating the support material to cause a curing reaction is not particularly limited and may be appropriately selected depending on the purpose. For example, the support material can be heated by applying energy by an energy applying means. Can be mentioned. As described above, in the heat curing method, the support material can be solidified by an energy applying means or the like without using a special means for solidifying the support material, so that the structure of the three-dimensional model manufacturing apparatus becomes complicated. Can be prevented. Further, in the heat curing method, the volume change when the support material is cured is small, and the strength of the support portion can be increased, so that the supporting force of the support portion with respect to the model portion can be further improved.

The support material in the heat curing method contains at least a reactive compound and a curing agent, and further contains other components if necessary.
The reactive compound is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include polymerizable compounds. Examples of the polymerizable compound include compounds having at least one ethylenically unsaturated double bond. The ethylenically unsaturated polymerizable compound has a chemical form of a monofunctional polymerizable compound, a polyfunctional polymerizable compound, or a mixture thereof.
The polymerizable compound is preferably a monofunctional polymerizable compound, and the monofunctional polymerizable compound includes, for example, esters of an unsaturated carboxylic acid and a polyhydric alcohol compound, and an unsaturated carboxylic acid and an amine compound. Amides, acryloylmorpholine, etc. That is, it is preferable that the support material in the heat curing method contains a monofunctional polymerizable compound. By doing so, since cross-linking does not occur in the support material, the solubility of the support portion in the liquid is increased, and the removability of the support portion can be improved.

Further, it is preferable that the thermal decomposition start temperature of the support portion is higher than the extrapolation melting end temperature of the resin particles. By doing so, it is possible to prevent the support portion from being decomposed by the heat applied from the resin particles, so that it is possible to suppress a decrease in the strength of the support portion during modeling, and the support force of the support portion with respect to the model portion can be increased. Can be more maintained.
Here, the thermal decomposition start temperature means the temperature at which a substance such as a resin starts to decompose due to an increase in temperature. The thermal decomposition start temperature can be, for example, a value measured by a method for measuring the thermal weight of plastic (JIS K7120). If the pyrolysis is a multi-step mass reduction, the pyrolysis start temperature shall be the primary start temperature.
Further, the extrapolation melting end temperature means the temperature at which the melting of a substance such as a resin is completed. The extrapolation melting end temperature can be, for example, a value measured by a plastic transition temperature measuring method (JIS K7121).

Here, the thermal decomposition start temperature of the support portion is more preferably higher than 380 ° C. By doing so, it becomes possible to more preferably use high melting point resin particles such as super engineering plastics. For example, PEEK (manufactured by VICTREX, 150PF), which is an example of super engineering plastic, has an extrapolation melting end temperature of 350 ° C.
Further, in the present invention, when the support material contains acryloylmorpholine, the removability of the support portion formed by solidifying the support material can be improved.

The curing agent is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include azo compounds and organic peroxides.
The other components of the support material in the heat curing method are not particularly limited and may be appropriately selected depending on the intended purpose. For example, a diluent, a polymerization inhibitor, a chain transfer agent, a colorant, a dispersion stabilizer, and a surfactant. Activators, penetration promoters, moisturizers, fungicides, preservatives, antioxidants, pH regulators, thickeners, fillers, anti-aggregation agents, antifoaming agents and the like.

An example of a specific composition of the support material in the heat curing method is shown below, but the support material in the heat curing method is not limited to this. Since the following example of the support material is soluble in water (water-soluble) after solidification, the support portion formed by the solidification of the support material can be easily immersed in water. Can be removed. Further, in the following example of the support material, the thermal decomposition start temperature of the support portion formed by solidifying the support material was 392 ° C.
・ Acryloylmorpholine (manufactured by Tokyo Chemical Industry Co., Ltd.): 97 parts by mass ・ t-butylperoxy-2-ethylhexyl monocarbonate (manufactured by Nippon Oil & Fats Co., Ltd.): 2 parts by mass ・ BYK-UV3530 (manufactured by BYK Ads & Instruments) ): 1 part by mass

The ultraviolet curing method is a method in which a support material that can be cured by being irradiated with ultraviolet rays is used, and the support area is irradiated with ultraviolet rays by an ultraviolet irradiation means to cure and solidify the support material.
The curing agent mixing method is a method of curing and solidifying the support material by discharging a curing agent capable of curing the support material to the support region.

[Removability of support part]
The support portion formed by solidifying the support material and adhering the resin particles to each other is usually removed from the model portion forming the three-dimensional model after the modeling of the three-dimensional object is completed. Therefore, it is preferable that the support portion has physical properties that can be easily removed from the model portion after the modeling of the three-dimensional object is completed.

The method for removing the support portion is not particularly limited and can be appropriately selected according to the purpose. For example, after blowing off excess powder adhering to the periphery of the three-dimensional model by an air blow or the like, the support portion is supported. A method of immersing a three-dimensional object having a portion in a liquid that selectively dissolves the support portion, or immersing the support portion in a liquid that selectively swells the support portion to reduce the mechanical strength of the support portion. Examples thereof include a method of peeling or breaking the support layer.

Among the above methods, a method of immersing a three-dimensional model having a support portion in a liquid that selectively dissolves the support portion is preferable. In other words, it is preferable to remove the support portion formed by the solidification of the support material by immersing it in a liquid that does not dissolve the resin particles. By doing so, the support portion can be easily removed in a short time, and the productivity at the time of manufacturing the three-dimensional model can be increased.
Further, when the support portion is removed by immersing the resin particles in a liquid that does not dissolve the resin particles, the support portion can be removed more easily by heating the liquid or applying ultrasonic vibration.

When a three-dimensional model having a support portion is immersed in a liquid that selectively dissolves the support portion to remove the support portion, the solidified support material can be a liquid that does not dissolve resin particles. It is preferably dissolved. By doing so, the support portion can be easily removed in a short time, and the productivity at the time of manufacturing the three-dimensional model can be increased.

The liquid that selectively dissolves the support unit is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include water, organic solvent, etc., such as safety, cost, and environmental load. From the viewpoint of, water is preferable.
When water is used as the liquid that selectively dissolves the support portion, the support material preferably contains a water-soluble adhesive component. The water-soluble adhesive component is not particularly limited and may be appropriately selected depending on the intended purpose. For example, acrylic acid, acrylamide, vinyl alcohol, ethyleneimine, ethylene oxide, N-vinyl-2-pyrrolidone, acryloylmorpholin. Such as polymerizable compounds or mixtures thereof, and polymers thereof.

<Energy applying means, energy applying process>
The energy applying means is a means for applying energy to the model region. The energy applying means, for example, applies energy to the model region to fuse the resin particles in the model region, and the resin particles in the model region and the resin particles in the support region in contact with the model region.
The energy applying step is a step of applying energy to the model region to fuse the resin particles in the model region, and the resin particles in the model region and the resin particles in the support region in contact with the model region.
The energy applying means is not particularly limited as long as it can be heated by applying energy to the particle layer, and can be appropriately selected depending on the intended purpose. For example, a light irradiating means for irradiating light or irradiating microwaves. Examples thereof include a microwave irradiation means for irradiating an electron beam and an electron beam irradiation means for irradiating an electron beam.

The energy applying means, for example, applies energy to the model region in the particle layer and heats the model region to fuse the resin particles in the model region to form a model portion that becomes a part of the three-dimensional model. Further, the energy applying means applies energy to the vicinity of the boundary between the model region and the support region in the particle layer and heats the particles to fuse the resin particles in the model region and the resin particles in the support region.
Further, the energy applying means preferably applies energy to the support region in the particle layer to heat the particles. By doing so, the solidification of the support material in the support region is promoted, and the support portion can be formed in a short time, so that the productivity of the three-dimensional model manufacturing apparatus can be improved.

Among those listed above, the energy applying means is preferably a light irradiation means. If the energy applying means is a light irradiation means and the model material can generate heat by absorbing light, the three-dimensional model can be efficiently modeled in a short time. Productivity can be improved.
The light irradiation means is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include halogen lamps, laser irradiation means, LED irradiation means, and xenon lamps.

Here, as a specific example product of the halogen lamp that can be used as the light irradiation means, for example, a line type halogen light source manufactured by Ushio, Inc. 3 W / mm (color temperature 3,000 K, energy density 0.04 W / mm ^2). ), Line type halogen light source manufactured by Ushio, Inc. 3 W / mm (color temperature 3,300 K, energy density 0.04 W / mm ² ) and the like.

Further, it is preferable that the energy applying means collectively fuses the resin particles in the model region and the resin particles in the model region and the resin particles in the support region adjacent to the model region. In other words, the energy applying means preferably performs the formation of the model portion and the fusion of the model portion and the support portion in one scan (collectively). By doing so, the three-dimensional model can be efficiently modeled in a short time, so that the productivity of the three-dimensional model manufacturing apparatus can be improved.

Here, the number of energy applying means included in the three-dimensional model manufacturing apparatus is not particularly limited and can be appropriately selected depending on the purpose.
When the three-dimensional model manufacturing apparatus has a plurality of light irradiation means as energy applying means, the fusion of the resin particles in the model region and the resin particles in the model region and the resin particles in the support region adjacent to the model region It is preferable that the fusion is performed by irradiating light with different energies. By doing so, it is possible to select an appropriate energy for the fusion of the resin particles in the model region and the fusion of the resin particles in the model region and the resin particles in the support region adjacent to the model region. It is possible to further improve the supporting force of the support unit with respect to the model unit.

Further, when the three-dimensional model manufacturing apparatus has a plurality of light irradiation means, the fusion of the resin particles in the model region and the resin particles in the support region adjacent to the model region is performed, and the fusion of the resin particles in the model region is performed. It is preferable to irradiate light having a wavelength shorter than the wavelength of the light to be irradiated at the time.
By doing so, for example, even when the support region is formed so as to be in contact with the lower side (lower surface) of the model region, the support region is located at the boundary between the model region and the support region by the highly transparent short wavelength light. The resin particles to be formed can be more reliably heated and fused. Therefore, the fusion of the resin particles in the model region and the resin particles in the support region adjacent to the model region is performed with a wavelength shorter than the wavelength of the light emitted when the resin particles in the model region are fused. By irradiating, the supporting force of the support portion with respect to the model portion can be further improved.

In this case, as the light irradiation means used for fusing the resin particles in the model region, for example, a line type halogen light source manufactured by Ushio, Inc. 3 W / mm (color temperature 3,000 K, energy density 0.04 W / mm ² ). Can be used. Further, as a light irradiation means used for fusing the resin particles in the model region and the resin particles in the support region, for example, a line type halogen light source manufactured by Ushio, Inc., 3 W / mm (color temperature 3,300 K, energy density 0. 04 W / mm ² ) can be used.

The temperature of the model region during heating is preferably equal to or higher than the extrapolation melting end temperature of the resin particles and lower than the thermal decomposition start temperature of the support portion. By doing so, it is possible to prevent the support portion from being decomposed by the heat applied from the resin particles, so that it is possible to suppress a decrease in the strength of the support portion during modeling, and the support force of the support portion with respect to the model portion can be increased. Can be more maintained.
Here, by setting the temperature of the model region during heating to be equal to or higher than the extrapolation melting end temperature of the resin particles, the resin can be more reliably melted. Further, by setting the temperature of the model region during heating to be lower than the thermal decomposition start temperature of the support portion, the thermal decomposition of the support portion can be prevented and the decrease in the strength of the support portion can be suppressed. It is possible to prevent the support unit from being peeled off or the support unit from being deformed so that the deformation of the model unit cannot be suppressed.
The temperature of the model region during heating can be adjusted, for example, by the preheating temperature of the particle layer (powder layer) and the energy application conditions. Examples of the energy application condition include the output of the light source and the time for applying energy.

<Other means>
The other means are not particularly limited and may be appropriately selected according to the purpose. For example, a maintenance means for suppressing the occurrence of discharge defects in the discharge means, a control means for controlling a three-dimensional model manufacturing apparatus, and the like. Can be mentioned.

The three-dimensional model manufacturing apparatus of the present invention manufactures (models) a three-dimensional model by repeatedly operating at least a layer forming means, a first discharging means, a second discharging means, and an energy applying means. be able to. Similarly, the method for manufacturing a three-dimensional model of the present invention manufactures (models) a three-dimensional model by repeating at least a layer forming step, a model region forming step, a support region forming step, and an energy applying step. be able to.

Here, the state of the interface between the model region (model unit) and the support region (support unit) will be described with reference to FIG. 23.
FIG. 23 is a photograph of a cross section of the interface between the model portion and the support portion. A sample prepared by using the modeling apparatus of the three-dimensional model of the present invention was embedded with an epoxy resin and then cross-sectioned with a glass knife to prepare a sample for photography. A digital microscope VHX-2000 (manufactured by KEYENCE CORPORATION) was used for taking the electron micrograph of FIG. 23.

In the electron micrograph shown in FIG. 23, it can be seen that the region indicated by reference numeral 301 is the resin particles in the model portion, and the particles are melted to eliminate the grain boundaries and are fused.
The region indicated by reference numeral 302 is an epoxy resin filled in the voids in the model portion when the embedding treatment is performed for cross-sectional observation.
It can be seen that the region indicated by reference numeral 303 is the interface between the model portion and the support portion, and the resin particles of the model portion and the support portion are melted to eliminate grain boundaries and are fused.
The region indicated by reference numeral 304 is the resin particles in the support portion, and the grain boundaries are recognized, indicating that the resin particles are adhered to each other.
The region indicated by reference numeral 305 is a region where the support material is solidified.

As described above, in the three-dimensional model manufacturing apparatus of the present invention, since the model portion and the support portion are fused, the deformation of the model portion can be suppressed by the supporting force of the support portion, and the modeling accuracy of the three-dimensional modeled object can be suppressed. Can be improved.

<Material set for 3D modeling>
The material set for three-dimensional modeling of the present invention can be suitably used for the apparatus for producing a three-dimensional model of the present invention and the method for producing a three-dimensional model of the present invention.
That is, the material set for three-dimensional modeling of the present invention is the material set for three-dimensional modeling used in the manufacturing apparatus for the three-dimensional model of the present invention or the method for producing the three-dimensional model of the present invention, and the support material and the resin particles are used. The thermal decomposition start temperature of the support portion formed by solidifying the support material becomes higher than the external melting end temperature of the resin particles (the thermal decomposition start temperature of the support portion is the external melting of the resin particles). Higher than the end temperature).
By doing so, it is possible to prevent the support portion from being decomposed by the heat applied from the resin particles, so that it is possible to suppress a decrease in the strength of the support portion during modeling, and the support force of the support portion with respect to the model portion can be increased. Can be more maintained.

Hereinafter, embodiments of the present invention will be described, but the present invention is not limited to these embodiments.
The number, position, shape, etc. of the following constituent members are not limited to the present embodiment, and may be a preferable number, position, shape, etc. for carrying out the present invention.

FIG. 10 is a schematic plan view of an embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 11 is a schematic side view of an embodiment of the three-dimensional model manufacturing apparatus of the present invention. FIG. 12 is a schematic side view showing a modeling portion in one embodiment of the three-dimensional model manufacturing apparatus of the present invention.

One embodiment of the device for manufacturing a three-dimensional model of the present invention shown in FIGS. 1 to 3 (hereinafter, may be simply referred to as a “three-dimensional model”) is a layered model formed by fusing resin particles. A first discharging means for discharging a model material and a support material for discharging a model material into a modeling part 1 on which a modeling layer (model part) 30 is formed and a particle layer 31 spread in layers of the modeling part 1 A discharge unit 5 as a discharge means of 2 and a light irradiation unit 80 as an energy applying means for irradiating the particle layer 31 with light 81 are provided. The model material and the support material may be collectively referred to as "modeling liquid 10".

The modeling unit 1 includes a particle tank 11 and a flattening roller 12 as a rotating body which is an example (flattening member, recorder) of the layer forming means. The flattening member may be, for example, a plate-shaped member (blade) instead of the rotating body.

The particle tank 11 has a supply tank 21 for supplying the resin particles 20 and a modeling tank 22 in which the modeling layer 30 is laminated to form a three-dimensional model. The resin particles 20 are supplied to the supply tank 21 before modeling. The bottom of the supply tank 21 can be raised and lowered in the vertical direction (height direction) as the supply stage 23. Similarly, the bottom of the modeling tank 22 can be raised and lowered in the vertical direction (height direction) as the modeling stage 24. A three-dimensional model in which the modeling layer 30 is laminated on the modeling stage 24 is modeled.

The supply stage 23 and the modeling stage 24 are moved up and down in the arrow Z direction (height direction) by a motor.

The flattening roller 12 supplies the particles 20 supplied on the supply stage 23 of the supply tank 21 to the modeling tank 22 and flattens them by the flattening roller 12 which is a flattening member to form the particle layer 31. To do.
The flattening roller 12 is arranged so as to be reciprocally movable relative to the stage surface in the arrow Y direction along the stage surface (the surface on which the resin particles 20 are loaded) of the modeling stage 24, and is arranged by the reciprocating movement mechanism. Will be moved. Further, the flattening roller 12 is rotationally driven by the motor 26.

The discharge unit 5 includes a liquid discharge unit 50 that discharges the modeling liquid 10 to the particle layer 31 on the modeling stage 24.
The liquid discharge unit 50 includes a carriage 51 and two (one or three or more) liquid discharge heads (hereinafter, simply referred to as “heads”) 52a and 52b 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 held on the side plates 70 and 70 on both sides so as to be able to move up and down.
The carriage 51 is in the arrow X direction (hereinafter, simply referred to as “X direction”), which is the main scanning direction, via a main scanning moving mechanism composed of a pulley and a belt by an X direction scanning motor 550 described later. The same applies to)).

The two heads 52a and 52b (hereinafter, referred to as "head 52" when not distinguished) are provided with a plurality of nozzle rows in which a plurality of nozzles for discharging liquid are arranged. The head 52 nozzle row discharges the modeling liquid 10. For example, the head 52a may discharge the model material, and the head 52b may discharge the support material. In this case, the head 52a is an example of the first discharging means, and the head 52b is an example of the second discharging means.
Further, the head 52 can also discharge colored modeling liquids such as cyan, magenta, yellow, and black. The head 52 is not limited to this.

A plurality of tanks 60 containing each of these modeling liquids are mounted on the tank mounting portion 56, and the modeling liquid 10 is supplied to the heads 52a and 52b via a supply tube or the like.
Further, on one side in the X direction, a maintenance mechanism 61 for maintaining and recovering the head 52 of the liquid discharge unit 50 is arranged.

The maintenance mechanism 61 has a cap 62 and a wiper 63. The maintenance mechanism 61 brings the cap 62 into close contact with the nozzle surface (the surface on which the nozzle is formed) of the head 52, and sucks the modeling liquid 10 from the nozzle to discharge particles clogged in the nozzle and to increase the viscosity of the modeling liquid. To discharge. Further, in order to form the meniscus of the nozzle (the inside of the nozzle is in a negative pressure state), the nozzle surface is wiped (wiped) with the wiper 63. The maintenance mechanism 61 covers the nozzle surface of the head with the cap 62 when the modeling liquid 10 is not discharged, and prevents the resin particles 20 from being mixed into the nozzles and the modeling liquid 10 from drying out.

The discharge unit 5 has a slider portion 72 movably held by a guide member 71 arranged on the base member 7, and the entire discharge unit 5 reciprocates in the Y direction (sub-scanning direction) orthogonal to the X direction. It is possible. The entire discharge unit 5 is reciprocated in the Y direction by a scanning mechanism including a motor 552 described later.

The liquid discharge unit 50 is arranged so as to be able to move up and down in the arrow Z direction together with the guide members 54 and 55, and is moved up and down in the Z direction by an elevating mechanism including a motor 551 described later.

The light irradiation unit 80 scans the region where the modeling liquid 10 is discharged from the head 52 while irradiating the light 81. By providing the light irradiation unit 80 in the carriage 51, it is possible to share the drive with the head 52, but by preparing a drive source individually, it is also possible to drive the light irradiation unit alone between the X directions. It is possible.
Further, the light irradiation unit 80 may be arranged on the left and right sides of the head 52, or may be arranged on either side.

Here, the details of the modeling unit 1 will be described.
The particle tank 11 is box-shaped and includes a supply tank 21, a modeling tank 22, and a surplus particle receiving tank 25, which are tanks having an open upper surface. 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 able to move up and down.

The side surface of the supply stage 23 is arranged so as to be in contact with the inner side surface of the supply tank 21. The side surface of the modeling stage 24 is arranged so as to be in contact with the inner surface 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 transfers and supplies the resin particles 20 from the supply tank 21 to the modeling tank 22 and flattens the surface by leveling the surface to form a particle layer 31 which is a layered particle group having a predetermined thickness.
The flattening roller 12 is a rod-shaped member longer than the inner dimensions of the modeling tank 22 and the supply tank 21 (that is, the width of the portion where the resin particles 20 are provided or the portion where the resin particles 20 are charged), and is staged by a reciprocating moving mechanism. It is reciprocated in the Y direction (secondary scanning direction) along the surface.
The flattening roller 12 moves horizontally while being rotated by the motor 26 so as to pass above the supply tank 21 and the modeling tank 22 from the outside of the supply tank 21. As a result, the resin particles 20 are transferred and supplied onto the modeling tank 22, and the particle layer 31 is formed by flattening the particles 20 while the flattening rollers 12 pass over the modeling tank 22.

Further, as shown in FIG. 12, a particle removing plate 13 which is a particle removing member for removing the resin particles 20 adhering to the flattening roller 12 in contact with the peripheral surface of the flattening roller 12 is arranged. There is.
The particle removing plate 13 moves together with the flattening roller 12 in contact with the peripheral surface of the flattening roller 12. Further, the particle removing plate 13 can be arranged in the forward direction even in the counter direction when the flattening roller 12 rotates in the rotation direction when flattening.

In the present embodiment, the particle tank 11 of the modeling unit 1 has three tanks, a supply tank 21, a modeling tank 22, and a surplus powder receiving tank 25, but the modeling is performed without providing the supply tank 21. Particles may be supplied to the tank 22 from the particle supply device and flattened by the flattening means.

Next, an outline of the control unit of the three-dimensional model manufacturing apparatus 601 will be described with reference to FIG.
The control unit 500 as a control means includes a CPU 501 that controls the entire three-dimensional modeling device, a program including a program for causing the CPU 501 to control a three-dimensional modeling operation including the control according to the present invention, and other fixed data. It includes a main control unit 500A including a ROM 502 for storing and a RAM 503 for temporarily storing modeling data and the like.

The control unit 500 includes a non-volatile memory (NVRAM) 504 for holding data even while the power of the device is cut off. Further, the control unit 500 includes an ASIC 505 that processes an image process that performs various signal processes on the image data and other input / output signals for controlling the entire device.

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 device 600. The modeling data creation device 600 is an device that creates modeling data by slicing a modeled object in the final form into each modeling layer, and can be realized by an information processing device such as a personal computer.

The control unit 500 includes an I / O 507 for capturing 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 discharge unit 50.
The control unit 500 drives the motor drive unit 510 that 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 discharge unit 5 in the Y direction (sub-scanning). It includes a motor drive unit 512 that drives a motor that constitutes a Y-direction scanning mechanism 552 that moves in the direction (direction).
The control unit 500 includes a motor drive unit 511 that drives a motor that constitutes a Z-direction elevating mechanism 551 that moves (elevates) the carriage 51 of the liquid discharge unit 50 in the Z direction. It should be noted that the elevating and lowering in the arrow Z direction may be configured to elevate and lower the entire discharge unit 5.
The control unit 500 includes a motor drive unit 513 that drives the motor 27 that raises and lowers the supply stage 23, and a motor drive unit 514 that drives the motor 28 that raises and lowers the modeling stage 24.
The control unit 500 includes a motor drive unit 515 that drives a motor 553 of a reciprocating movement mechanism that moves the flattening roller 12, and a 516 that drives a motor 26 that rotationally drives the flattening roller 12.
The control unit 500 includes a supply system drive unit that drives the particle supply device that supplies the particles 20 to the supply tank 21, and a maintenance drive unit 518 that drives the maintenance mechanism 61 of the liquid discharge unit 50.
A detection signal such as a temperature / humidity sensor 560 that detects temperature and humidity as an environmental condition of the device and a detection signal of other sensors are input to the I / O 507 of the control unit 500.
An operation panel 522 for inputting and displaying information necessary for this device is connected to the control unit 500.

Next, the flow of manufacturing (modeling) of the three-dimensional model will be described with reference to FIGS. 14A to 14F. 14A to 14F are schematic views showing an example of the flow of modeling of a three-dimensional model.
The state in which the first modeling layer 30 is formed on the modeling stage 24 of the modeling tank 22 will be described.
When the next modeling layer 30 is formed on the modeling layer 30, as shown in FIG. 14A, 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 (particle layer surface) of the modeling tank 22 and the lower portion (lower tangential portion) of the flattening roller 12 is Δt. This interval Δt corresponds to the thickness of the particle layer 31 to be formed next. The interval Δt is preferably about several tens to 100 μm.

Next, as shown in FIG. 14B, the particles 20 located above the upper surface level of the supply tank 21 are moved in the Y2 direction (modeling tank 22 side) while rotating the flattening roller 12 in the forward direction (arrow direction). By doing so, the resin particles 20 are transferred and supplied to the modeling tank 22 (particle supply).

Further, as shown in FIG. 14C, 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. 14D, a predetermined thickness is formed on the modeling layer 30 of the modeling stage 24. A particle layer 31 having Δt is formed (flattening). After forming the particle layer 31, the flattening roller 12 is moved in the Y1 direction and returned to the initial position as shown in FIG. 14D.

Here, the flattening roller 12 can move while keeping a constant distance from the upper surface level of the modeling tank 22 and the supply tank 21. By being able to move while being kept constant, the flattening roller 12 conveys the resin particles 20 onto the modeling tank 22, and the particle layer having a uniform thickness Δt is placed on the modeling tank 22 or the already formed modeling layer 30. 31 can be formed.

Then, as shown in FIG. 14E, droplets of the modeling liquid 10 are discharged from the head 52 of the liquid discharge unit 50 to a desired position in the modeling tank 22 to form at least one of a model region and a support region. Then, as shown in FIG. 14F, the light irradiation unit 80 heats the particle layer 31 and fuses the resin particles to each other by scanning on the modeling tank 22 while irradiating the light 81, and the model unit (modeling layer). ) 30 and at least one of the support portions.

Next, a new molding layer 30 is formed by repeating the steps of forming the particle layer 31 by supplying and flattening the resin particles, the molding liquid ejection step by the head 52, and the energy applying step by the light irradiation unit 80. At this time, the new modeling layer 30 and the underlying modeling layer 30 are integrated into a part of the three-dimensional shaped model.
After that, by repeating the process of forming the particle layer 31 by supplying and flattening the resin particles, the process of discharging the modeling liquid by the head 52, and the heating by the light irradiation unit 80 as many times as necessary, the three-dimensional shaped object (three-dimensional model). To manufacture.

FIG. 15 is an explanatory diagram showing an example of a flow when forming a support region.
First, as shown in the left portion of FIG. 15, the flattening roller 12 is rotated and moved in the direction of the arrow Y2 to form the particle layer 31 containing the resin particles 20. Next, as shown in the central portion of FIG. 15, the support material (support ink, support liquid composition) 10s is discharged to the particle layer 31 by the head 52 to form the support region 201. Then, as shown on the right side of FIG. 15, the support material 10s in the formed support region is solidified by heat from the preheated resin particles 20 or the like to become the solidified support material 202. The solidified support material 202 adheres the resin particles 20 to each other to form the support portion 200.

FIG. 16 is an explanatory diagram showing an example of a flow when forming a model region and a model portion.
First, as shown in the left portion of FIG. 16, the flattening roller 12 is rotated and moved in the direction of arrow Y2 on the particle layer 31 in which the support portion 200 formed by the operation shown in FIG. 15 exists. , A new particle layer 31 is formed. Next, as shown in the central portion of FIG. 16, the model material (model ink, model liquid composition) 10 m is discharged to the particle layer 31 by the head 52 to form the model region 101.
Then, as shown in the right part of FIG. 16, the resin particles 20 in the formed model region 101 are heated by the light 81 irradiated by the light irradiation unit 80, and the model material 10 m absorbs the light 81 to generate heat. As a result, the resin particles 20 are fused to each other to form a model portion (modeling layer) 30. At this time, the resin particles 20 in a part of the model region 101 and the resin particles 20 in a part of the support region 201 (support portion 200) are also heated by the light 81 irradiated by the light irradiation unit 80 and fused.
By repeating the process shown in FIG. 16 a predetermined number of times, the model portions 30 are laminated to produce a three-dimensional model.

Here, for example, in the case of manufacturing the rectangular parallelepiped three-dimensional object shown in FIG. 9, a model region formed by the first discharge means and a support region formed by the second discharge means. When is formed in one particle layer, there is a portion where the model portion 30 and the support portion 200 are adjacent to each other. In such a case, it is preferable that the model region formed by the first discharging means is formed before the support region formed by the second discharging means.

For example, as shown in FIG. 24, when the support portion 200 is provided at the bottom end side of the model portion 30, the model portion surface 30a adjacent to (contacting) the support portion 200 on the vertical surface of the model portion 30. And the model portion surface 30b that is not adjacent (not in contact with) the support portion 200 exists. In this case, when the model unit 30 and the support unit 200 are formed in one particle layer, the model region formed by the first ejection means is formed in the portion where the model unit 30 and the support unit 200 are adjacent to each other. By forming the support region before the support region formed by the second ejection means, the difference in surface properties between the model portion surface 30a adjacent to the support portion 200 and the model portion surface 30b not adjacent to the support portion 200 can be obtained. It can be made smaller.
That is, when the model portion 30 and the support portion 200 are formed in one particle layer, the model portion 30 is formed first, so that the model material is discharged in the vicinity of the solidified support material, whereby the model material is formed. Permeation and heat transfer differ between the model material located near the support material and the model material not located in the vicinity of the support material, and it is possible to suppress a difference in the surface properties of the modeled model portion 30. Further, when the model portion 30 and the support portion 200 are formed in one particle layer, the model portion 30 is formed first so that the model portion surface 30a adjacent to the support portion 200 and the support portion 200 are not adjacent to each other. It is possible to prevent the formation of a step or the like with the model portion surface 30b.

FIG. 25 is a schematic side view showing another example of the model unit and the support unit in the three-dimensional model manufacturing apparatus of the present invention.
When modeling the model portion 30 having the eaves portion (overhang portion) 32 as shown in FIG. 25, the eaves portion 32 has a thin plate-like shape and is considered to be easily deformed during modeling. It is preferable to support it by the support unit 200. Also in the example shown in FIG. 25, on the vertical surface of the model unit 30, the model unit surface 30a adjacent to (contacting) the support unit 200 and the model unit surface 30b not adjacent to (contacting) the support unit 200 are formed. Exists.
Therefore, even when modeling the model portion 30 having the shape shown in FIG. 25, the model region formed by the first discharge means is formed before the support region formed by the second discharge means. Is preferable. In other words, when the model region and the support region are adjacent to each other in one particle layer, the model region is formed by the first discharge means before the support region is formed by the second discharge means. It is preferable to do so. By doing so, it is possible to reduce the difference in surface properties between the model portion surface 30a adjacent to the support portion 200 and the model portion surface 30b not adjacent to the support portion 200.

FIG. 26 is an explanatory diagram showing an example of a flow when forming a model region and a model portion in one particle layer.
In the example shown in FIG. 26, first, the flattening roller 12 is rotated and moved in the direction of the arrow Y2 to form the particle layer 31 containing the resin particles 20. Further, when the particle layer 31 is formed, the resin particles 20 are heated so that the temperature of the resin particles 20 becomes a desired preheating temperature. Next, the head 52 ejects 10 m of the model material (model ink, model liquid composition) to the particle layer 31 to form the model region 101. Subsequently, the head 52 ejects the support material (support ink, support liquid composition) 10s to the particle layer 31 to form the support region 201. When a heat-curing support material is used for the support material 10s, the heat energy at a desired preheating temperature causes a polymerization reaction to occur in the reactive compound of the support material 10s, and the support material solidifies. The resin particles 20 are adhered to each other to form the support portion 200.
Next, the resin particles 20 in the formed model region 101 are heated by irradiating the light 81 from the light irradiation unit 80, and the model material 10 m absorbs the light 81 to generate heat, so that the resin particles 20 are melted together. It is worn to form a model portion (modeling layer) 30. At this time, the resin particles 20 in a part of the model region 101 and the resin particles 20 in a part of the support region 201 (support portion 200) are also heated by the light 81 irradiated by the light irradiation unit 80 and fused.

FIG. 27 is a schematic side view showing an example of the structure of the carriage in the three-dimensional model manufacturing apparatus.
In the example shown in FIG. 27, two heads 52a and 52b are mounted on the carriage 51, and the head 52a (an example of the first discharging means) uses the model material 10m and the head 52b (the second discharging means). (Example) discharges the support material 10s. For example, when the carriage 51 is moving in the direction indicated by the arrow X2, the heads 52a and 52b are driven and the model material 10 m and the support material 10s are discharged in this order, whereby the model material 10 m is applied to the particle layer 31. Lands first, and then the support material 10s lands. By doing so, the model region formed by the first discharge means can be formed before the support region formed by the second discharge means.

FIG. 28 is a schematic top view showing an example of a carriage in a three-dimensional model manufacturing apparatus.
In the example shown in FIG. 28, the model material discharge heads 52a1 and 52a2 are arranged on both sides of the support material discharge head 52b in the carriage 51. In the example shown in FIG. 28, when the carriage 51 is moving in the direction of the arrow X2, the head 52a1 is used to discharge the model material, and the head 52b is used to discharge the support material. On the other hand, when the carriage 51 is moving in the direction of the arrow X1, the head 52a2 is used to discharge the model material, and the head 52b is used to discharge the support material. By doing so, the model material can be discharged before the support material regardless of which of the arrows X1 and X2 the carriage is moving.

When the carriage 51 is operated in both directions as described above, the carriage 51 is moved in the direction of the arrow X1 to discharge the model material and the support material, and then the carriage 51 remains on standby on the right side of FIG. 28. The flattening roller 12 supplies the resin particles to the molding tank 22, and the flattening roller 12 uniformly flattens the particles. After that, the carriage 51 is moved in the direction of the arrow X2 to discharge the model material and the support material.
In the example shown in FIG. 28, since the model material and the support material can be discharged in both directions, it is not necessary to return the carriage to the home position after the discharge is completed once, and the modeling speed can be increased. ..

Further, as shown in FIG. 29, unlike the example shown in FIG. 28, the support material discharge heads 52b1 and 52b2 may be arranged on both sides of the model material discharge head 52a in the carriage 51.
In the example shown in FIG. 29, when the carriage 51 is moving in the direction of the arrow X2, the head 52a is used to discharge the model material, and the head 52b2 is used to discharge the support material. On the other hand, when the carriage 51 is moving in the direction of the arrow X1, the head 52a is used to discharge the model material, and the head 52b1 is used to discharge the support material. By doing so, the model material can be discharged before the support material regardless of which of the arrows X1 and X2 the carriage is moving.

Further, in the examples shown in FIGS. 28 and 29, an example in which the model material discharge head 52a and the support material discharge head 52b are mounted on one carriage is shown, but the present invention is not limited thereto. .. In other words, in the present invention, the first discharging means and the second discharging means may be arranged integrally or separately.
For example, as shown in FIG. 30, the model material discharge head 52a and the support material discharge head 52b may be mounted on separate carriages 51a and 51b. By doing so, the head 52a and the head 52b can be moved independently, and the time from the formation of the model region to the formation of the support region can be easily changed. In other words, it is preferable that the first discharging means and the second discharging means are arranged separately and can be moved independently.
When the material of the resin particles and the type of the model material are changed, the time for the model material to permeate into the resin particles and the time for the model material to melt and solidify may change. In the example shown in FIG. 30, even when the materials are changed, it is possible to easily set the conditions suitable for each material.

FIG. 17 is an explanatory diagram showing an example of a flow when removing the support portion from the three-dimensional modeled object.
First, as shown in the left portion of FIG. 17, the resin particles 20 adhering to the periphery of the three-dimensional model in which the model portion 30 is laminated are removed by blowing the wind 90 generated by an air blower or the like. Next, as shown in the right part of FIG. 17, the three-dimensional model and the support portion 200 are immersed in the solidified support material 202 in a soluble liquid 91, and the support portion 200 is removed from the three-dimensional model to finally complete the process. A three-dimensional model having a desired shape is produced.

FIG. 18 is a diagram showing an example of a support portion formed by using the solvent volatilization method.
As shown in FIG. 18, in the solvent volatilization method, since the support portion 200 is formed by volatilizing the solvent of the support material 10s, the volume of the solidified support material 202 is larger than the volume of the discharged support material 10s. It becomes smaller. Therefore, in the solvent volatilization method, as shown in FIG. 18, it is considered that the solidified support material 202 is in a state of being coated around the resin particles 20.
As described above, in the solvent volatilization method, for example, the discharged support material 10s is heated by the preheating of the resin particles 20 or the light 81 given by the light irradiation unit 80, and the solvent is volatilized to solidify. Then, the support unit 200 is formed.

FIG. 19 is a diagram showing an example of a support portion formed by using a heat curing method.
As shown in FIG. 19, in the heat curing method, since the support portion 200 is formed by causing a polymerization reaction in the reactive compound of the support material 10s, the solidified support material 202 is more than in the case of using the solvent volatilization method. The amount of decrease in volume of Therefore, in the heat curing method, as shown in FIG. 18, it is considered that the solidified support material 202 fills the space between the resin particles 20.
As described above, in the heat curing method, for example, the discharged support material 10s is heated by the preheating of the resin particles 20 or the light 81 given by the light irradiation unit 80 to activate the curing agent. The support portion 200 is formed by causing the reactive compound to undergo a polymerization reaction.

FIG. 20 is an explanatory diagram showing an example of a flow when resin particles are fused by using a plurality of light irradiation means.
First, as shown in the first portion from the left in FIG. 20, similarly to the left portion in FIG. 16, the flattening roller 12 is rotated on the particle layer 31 in which the support portion 200 is present, and the arrow Y2 is shown. By moving in the direction, a new particle layer 31 is formed. Next, as shown in the second portion from the left in FIG. 20, the model material (model ink) 10 m is discharged to the particle layer 31 by the head 52 as in the central portion of FIG. 16, and the model region 101 To form.
Then, as shown in the third portion from the left in FIG. 20, the resin particles 20 in the formed model region 101 are heated by the light 81a irradiated by the first light irradiation unit 80a, and the model material 10 m is illuminated. By absorbing 81 and generating heat, the resin particles 20 are fused to each other to form a model portion (modeling layer) 30. Subsequently, as shown in the fourth portion from the left in FIG. 20, the resin particles 20 in a part of the model region 101 and the resin particles 20 in a part of the support region 201 (support portion 200) are seconded. It is heated and fused by the light 81b irradiated by the light irradiation unit 80b.

At this time, in the light 81a emitted by the first light irradiation unit 80a and the light 81b irradiated by the second light irradiation unit 80b, as shown in FIG. 21, the light emitted by the second light irradiation unit 80b 81b has a peak on the short wavelength side. By doing so, as shown in FIG. 20, even when the support region 201 is formed below the model region 101, the model region 101 and the support region 201 (or the support region 201 (or) are generated by the highly transparent short wavelength light. The resin particles located at the boundary of the support portion 200) can be more reliably heated and fused.

Next, an example of the flow of the modeling operation in the method for manufacturing the three-dimensional model of the present invention will be described.

FIG. 22 is a flowchart showing an example of the flow of processing for performing the modeling operation. Here, an example of the flow of the process of performing the modeling operation will be described according to the step represented by S in the flowchart of the flowchart shown in FIG.

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

In step S102, the control unit 500 starts a modeling operation based on the modeling data, and when each unit such as the head 52 is moved to the initial position by each drive unit, the process shifts to S103.

In step S103, when the control unit 500 drives the flattening roller 12 to form the particle layer 31 containing the resin particles 20, the process shifts to S104.

In step S104, when the control unit 500 determines that the discharge position of the head 52 is the model area based on the modeling data, the process shifts to S105. Further, when the control unit 500 determines that the discharge position of the head 52 is not in the modeling region, the process shifts to S106.

In step S105, when the control unit 500 discharges the model material 10 m to the head 52, the process shifts to S108.

In step S106, when the control unit 500 determines that the discharge position of the head 52 is the support region based on the modeling data, the process shifts to S107. Further, when the control unit 500 determines that the head 52 is not in the discharge position support region, the process shifts to S108.

In step S107, when the control unit 500 discharges the support material 10s to the head 52, the process shifts to S108.

In step S108, when the control unit 500 determines that the ejection operation of the particle layer 31 is completed, the process shifts to S110. Further, when the control unit 500 determines that the ejection operation of the particle layer 31 has not been completed, the process shifts to S109.

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

In step S110, the control unit 500 irradiates the particle layer 31 with light 81 by the light irradiation unit 80 to heat the particle layer 31. Here, the resin particles 20 in the model region in the particle layer 31 are fused to each other, and the resin particles 20 in the model region and the resin particles 20 in the support region are also fused.

In step S111, when the control unit 500 determines that the modeling operation based on the modeling data has not been completed, the process returns to S103. Further, when the control unit 500 determines that the modeling operation based on the modeling data is completed, the control unit 500 ends this process.

Examples of the present invention will be described below, but the present invention is not limited to these examples.

(Example 1)
Using a three-dimensional model manufacturing device as shown in FIG. 10, a support area is formed so as to be in contact with the lower side (lower surface) of the model area, and one layer of the model part is formed on the support part. 1 was modeled. When modeling the model portion, the temperature of the model region when the model region was heated was measured with a thermo camera (manufactured by OPTRIS, Xi-80).

As the resin particles contained in the particle layer, PEEK (manufactured by VICTREX, 150PF) was used.
As the support material, a material having the following composition was used. The thermal decomposition start temperature of the support portion formed by the solidification of the support material was 392 ° C.
・ Acryloylmorpholine (manufactured by Tokyo Chemical Industry Co., Ltd.): 97 parts by mass ・ t-butylperoxy-2-ethylhexyl monocarbonate (manufactured by Nippon Oil & Fats Co., Ltd.): 2 parts by mass ・ BYK-UV3530 (manufactured by BYK Ads & Instruments) ): 1 part by mass

Further, in Example 1, the average thickness of the particle layer was 0.1 mm, and the size of the model region and the support region in the plane direction was 1 cm × 1 cm. As a model material, black ink (LMOPI11AKK manufactured by Nazdar Ink Technologies) was used.
In Example 1, the preheating temperature of the particle layer was set to 160 ° C., and the particle layer was heated for 3.6 seconds using a halogen lamp having an output of 383 W. The maximum temperature reached in the model region during heating was 380 ° C.

<Observation>
When the model 1 obtained as described above was observed using a digital microscope (manufactured by KEYENCE, VHX-2000), the resin particles in the model region were melted to form a model portion. In addition, the model part and the support part were fused, and the model part did not deform even after modeling.

In the same way, the state of yellowing on the surface of the support portion was observed. Here, if the surface of the support portion is yellowed, it can be considered that the solidified support material is thermally decomposed.
In Example 1, yellowing did not occur on the surface of the support portion. The observation results are shown in Table 1.

(Example 2)
In Example 1, the model 2 was modeled in the same manner as in Example 1 except that the preheating temperature of the particle layer was 190 ° C., the output of the halogen lamp was 340 W, and the heating time was 5.0 seconds. The maximum temperature reached in the model region during heating was 385 ° C.

When the model 2 was observed in the same manner as in Example 1, the resin particles in the model region were melted to form the model portion. In addition, the model part and the support part were fused, and the model part did not deform even after modeling. No yellowing occurred on the surface of the support portion. The results are shown in Table 1.

(Example 3)
In Example 1, PA12 (PA2200 manufactured by EOS) was used as the resin particles, the preheating temperature of the particle layer was 120 ° C., the output of the halogen lamp was 745 W, and the heating time was 0.7 seconds. The model 3 was modeled in the same manner as above. The maximum temperature reached in the model region during heating was 322 ° C.

When the model 3 was observed in the same manner as in Example 1, the resin particles in the model region were melted to form the model portion. In addition, the model part and the support part were fused, and the model part did not deform even after modeling. No yellowing occurred on the surface of the support portion. The results are shown in Table 1.

(Example 4)
In Example 3, the model 4 was modeled in the same manner as in Example 3 except that the output of the halogen lamp was 373 W. The maximum temperature reached in the model region during heating was 245 ° C.

When the model 4 was observed in the same manner as in Example 1, the resin particles in the model region were melted to form the model portion. In addition, the model part and the support part were fused, and the model part did not deform even after modeling. No yellowing occurred on the surface of the support portion. The results are shown in Table 1.

(Comparative Example 1)
In Example 1, the modeling process of the modeled object was performed in the same manner as in Example 1 except that the output of the halogen lamp was 213 W and the heating time was 8.0 seconds. The maximum temperature reached in the model region during heating was 280 ° C.
In Comparative Example 1, since the temperature reached in the model region during heating was lower than the extrapolation end temperature of the resin particles, the resin particles in the model region did not melt (fuse), and the model portion could be modeled. became. Therefore, no observation was made except for the presence or absence of yellowing on the surface of the support portion. The results are shown in Table 1.

(Comparative Example 2)
In Example 2, the modeling process of the modeled object was performed in the same manner as in Example 2 except that the output of the halogen lamp was 425 W and the heating time was 2.0 seconds. The maximum temperature reached in the model region during heating was 380 ° C.
In Comparative Example 2, although the temperature reached in the model region during heating was higher than the replacement end temperature of the resin particles, the heating time was not sufficient, the resin particles were insufficiently melted, and the resin particles were fused together. I couldn't do it, and I couldn't model the model part. Therefore, no observation was made except for the presence or absence of yellowing on the surface of the support portion. The results are shown in Table 1.

(Comparative Example 3)
In Example 3, the modeling process of the modeled object was performed in the same manner as in Example 3 except that the output of the halogen lamp was set to 298 W. The maximum temperature reached in the model region during heating was 196 ° C.
In Comparative Example 3, although the temperature reached in the model region during heating was higher than the replacement end temperature of the resin particles, the heating time was not sufficient, the resin particles were insufficiently melted, and the resin particles were fused together. I couldn't do it, and I couldn't model the model part. Therefore, no observation was made except for the presence or absence of yellowing on the surface of the support portion. The results are shown in Table 1.

(Comparative Example 4)
In Example 3, the modeling process of the modeled object was performed in the same manner as in Example 3 except that the output of the halogen lamp was set to 260 W.
In Comparative Example 4, since the temperature reached in the model region during heating was lower than the extrapolation end temperature of the resin particles, the resin particles in the model region did not melt (fuse), and the model portion could be formed. became. Therefore, no observation was made except for the presence or absence of yellowing on the surface of the support portion. The results are shown in Table 1.

As shown in Table 1, in Examples 1 to 4 which are examples of the present invention, the resin particles in the model region (model part) and the resin particles in the model region and the resin particles in the support region in contact with the model region It can be seen that the models (model part and support part) are fused to each other and the deformation of the model part is suppressed.

As described above, the apparatus for manufacturing a three-dimensional model of the present invention forms a model region by discharging a layer forming means for forming a particle layer containing resin particles and a model material capable of absorbing energy into the particle layer. A first discharging means for forming a support region by discharging a support material to the particle layer, and an energy applying means for applying energy to the model region are provided, and energy is provided for the model region. Is given to fuse the resin particles in the model region and the resin particles in the model region and the resin particles in the support region in contact with the model region.
As a result, the apparatus for manufacturing the three-dimensional model of the present invention can suppress the deformation of the three-dimensional model formed by heating the resin particles and improve the modeling accuracy of the three-dimensional model.

Examples of aspects of the present invention are as follows.
<1> A layer forming means for forming a particle layer containing resin particles and
A first ejection means for forming a model region by ejecting a model material capable of absorbing energy into the particle layer,
A second ejection means for ejecting a support material into the particle layer to form a support region, and
An energy applying means for applying the energy to the model region is provided.
By applying the energy to the model region, the resin particles in the model region and the resin particles in the model region and the resin particles in the support region in contact with the model region are fused to each other. To be done,
It is a manufacturing apparatus for a three-dimensional model characterized by.
<2> The apparatus for manufacturing a three-dimensional model according to <1>, wherein the resin particles in the support region are adhered to each other by solidifying the support material discharged by the second discharge means.
<3> When the layer forming means forms the second particle layer on the first particle layer,
Any of the above <1> to <2> forming the support region in the first particle layer so that the second ejection means comes into contact with the planned portion to be the model region in the second particle layer. It is a manufacturing apparatus for a three-dimensional model described in Crab.
<4> When the layer forming means forms the second particle layer on the first particle layer,
The solid according to any one of <1> to <2>, wherein the second ejection means forms the support region in the region of the second particle layer in contact with the model region of the first particle layer. It is a manufacturing device for shaped objects.
<5> The model region formed by the first ejection means and the support region formed by the second ejection means are formed in one particle layer from <1> to <4. > Is a three-dimensional model manufacturing apparatus according to any one of.
<6> When forming a portion in which the model region and the support region are adjacent to each other in the one particle layer,
The device for manufacturing a three-dimensional model according to <5>, wherein the model region is formed by the first discharge means before the support region is formed by the second discharge means.
<7> The solid according to any one of <1> to <6>, wherein the support region is formed so that the second discharge means is in contact with at least a part of a region near the outer edge of the model region. It is a manufacturing device for shaped objects.
<8> The apparatus for manufacturing a three-dimensional model according to any one of <1> to <7>, wherein the first discharging means and the second discharging means are integrally arranged.
<9> The three-dimensional model according to any one of <1> to <7>, wherein the first discharge means and the second discharge means are arranged separately and can be moved independently. It is a manufacturing equipment of.
<10> The energy applying means collectively fuses the resin particles in the model region with each other and the resin particles in the model region and the resin particles in the support region in contact with the model region. The apparatus for manufacturing a three-dimensional model according to any one of <1> to <9>.
<11> The energy applying means is a light irradiating means for irradiating light.
The three-dimensional model according to any one of <1> to <10>, wherein the model material discharged by the first discharge means can generate heat by absorbing the light irradiated by the light irradiation means. It is a manufacturing equipment.
<12> The light irradiation means differs between the fusion of the resin particles in the model region and the fusion of the resin particles in the model region and the resin particles in the support region in contact with the model region. The apparatus for manufacturing a three-dimensional model according to <11>, which is performed by irradiating the light of the energy.
<13> The light irradiation means irradiates the fusion of the resin particles in the model region with the resin particles in the support region in contact with the model region at the time of fusion of the resin particles in the model region. The apparatus for manufacturing a three-dimensional model according to <12>, which is performed by irradiating the light having a wavelength shorter than the wavelength of the light.
<14> The apparatus for manufacturing a three-dimensional model according to any one of <1> to <13>, wherein the support material is solidified by volatilizing a part of the support material discharged by the second discharge means. Is.
<15> The three-dimensional model manufacturing apparatus according to <14>, wherein the support material discharged by the second discharging means is capable of absorbing the energy.
<16> The apparatus for manufacturing a three-dimensional model according to any one of <1> to <13>, wherein the support material discharged by the second discharging means solidifies by causing a polymerization reaction.
<17> The apparatus for producing a three-dimensional model according to any one of <15> to <16>, wherein the solidified support material is soluble in a liquid that does not dissolve the resin particles.
<18> A layer forming step of forming a particle layer containing resin particles, and
A model region forming step of ejecting a model material capable of absorbing energy into the particle layer to form a model region,
A support region forming step of ejecting a support material into the particle layer to form a support region,
An energy applying step of applying the energy to the model region to fuse the resin particles in the model region with each other and the resin particles in the model region and the resin particles in the support region in contact with the model region. When,
It is a method for manufacturing a three-dimensional model, which is characterized by including.
<19> The support portion formed by solidifying the support material is removed by immersing the model portion formed by fusing the resin particles in the model region with an insoluble liquid. > Is a method for manufacturing a three-dimensional model.
<20> The method for producing a three-dimensional model according to any one of <18> to <19>, further comprising a preheating step of preheating the resin particles so that the temperature of the resin particles becomes a desired preheating temperature. Is.
<21> The support material contains an adhesive component for adhering the resin particles to each other and a solvent.
The method for producing a three-dimensional model according to <20>, wherein at least one of the melting point and the softening point of the adhesive component is higher than the preheating temperature and the boiling point of the solvent is lower than the preheating temperature.
<22> The method according to any one of <18> to <21>, wherein the thermal decomposition start temperature of the support portion formed by solidifying the support material is higher than the extrapolation melting end temperature of the resin particles. This is a method for manufacturing a three-dimensional model.
<23> The method for manufacturing a three-dimensional model according to <22>, wherein the thermal decomposition start temperature of the support portion is higher than 380 ° C.
<24> From <22>, wherein the temperature of the model region when performing the energy application step is higher than the external melting end temperature of the resin particles and lower than the thermal decomposition start temperature of the support portion. The method for manufacturing a three-dimensional model according to any one of <23>.
<25> For three-dimensional modeling used in the three-dimensional model manufacturing apparatus according to any one of <1> to <17> or the three-dimensional model manufacturing method according to any one of <18> to <24>. It's a material set
It has the support material and the resin particles,
The three-dimensional modeling material set is characterized in that the thermal decomposition start temperature of the support portion formed by solidifying the support material is higher than the extrapolation melting end temperature of the resin particles.

The apparatus for manufacturing a three-dimensional model according to any one of <1> to <17>, the method for manufacturing a three-dimensional model according to any one of <18> to <24>, and the above-mentioned <25>. According to the three-dimensional modeling set, various problems in the past can be solved and the object of the present invention can be achieved.

International Publication No. 2017/162306 Japanese Unexamined Patent Publication No. 2016-155367

10m model material 10s support material 12 Flattening roller (part of layer forming means)
20 Resin particles 30 Model part (modeling layer)
31 Particle layer 52 Head (example of ejection means)
80 Light irradiation unit (part of energy application means)
101 Model area 200 Support unit 201 Support area 601 Manufacturing equipment for three-dimensional objects

Claims (25)

A layer forming means for forming a particle layer containing resin particles,
A first ejection means for forming a model region by ejecting a model material capable of absorbing energy into the particle layer,
A second ejection means for ejecting a support material into the particle layer to form a support region, and
An energy applying means for applying the energy to the model region is provided.
By applying the energy to the model region, the resin particles in the model region and the resin particles in the model region and the resin particles in the support region in contact with the model region are fused to each other. To be done,
A three-dimensional model manufacturing device characterized by. The apparatus for manufacturing a three-dimensional model according to claim 1, wherein the resin particles in the support region are adhered to each other by solidifying the support material discharged by the second discharge means. When the layer forming means forms a second particle layer on the first particle layer,
The invention according to any one of claims 1 to 2, wherein the support region of the first particle layer is formed so that the second ejection means comes into contact with a planned portion to be the model region of the second particle layer. Manufacturing equipment for three-dimensional objects. When the layer forming means forms a second particle layer on the first particle layer,
The three-dimensional model according to any one of claims 1 to 2, wherein the second ejection means forms the support region in the region of the second particle layer in contact with the model region of the first particle layer. Manufacturing equipment. The method according to any one of claims 1 to 4, wherein the model region formed by the first ejection means and the support region formed by the second ejection means are formed in one particle layer. Manufacturing equipment for three-dimensional objects. When forming a portion in which the model region and the support region are adjacent to each other in the one particle layer,
The device for manufacturing a three-dimensional model according to claim 5, wherein the model region is formed by the first discharge means before the support region is formed by the second discharge means. The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 6, wherein the support region is formed so that the second discharge means is in contact with at least a part of a region near the outer edge of the model region. The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 7, wherein the first discharging means and the second discharging means are integrally arranged. The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 7, wherein the first discharging means and the second discharging means are arranged separately and can be moved independently. A claim that the energy applying means collectively performs fusion of the resin particles in the model region and fusion of the resin particles in the model region and the resin particles in the support region in contact with the model region. Item 4. The apparatus for manufacturing a three-dimensional model according to any one of Items 1 to 9. The energy applying means is a light irradiating means for irradiating light.
The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 10, wherein the model material discharged by the first discharge means can generate heat by absorbing the light irradiated by the light irradiation means. The light irradiation means has different energies for fusion of the resin particles in the model region and fusion of the resin particles in the model region and the resin particles in the support region in contact with the model region. The apparatus for manufacturing a three-dimensional model according to claim 11, which is performed by irradiating the light. The light that the light irradiation means irradiates the fusion of the resin particles in the model region and the resin particles in the support region in contact with the model region at the time of fusion of the resin particles in the model region. The apparatus for manufacturing a three-dimensional model according to claim 12, wherein the light having a wavelength shorter than that of the above-mentioned light is irradiated. The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 13, wherein the support material is solidified by volatilizing a part of the support material discharged by the second discharge means. The device for manufacturing a three-dimensional model according to claim 14, wherein the support material discharged by the second discharging means can absorb the energy. The apparatus for manufacturing a three-dimensional model according to any one of claims 1 to 13, wherein the support material discharged by the second discharging means solidifies by causing a polymerization reaction. The apparatus for manufacturing a three-dimensional model according to any one of claims 15 to 16, wherein the solidified support material is soluble in a liquid that does not dissolve the resin particles. A layer forming process for forming a particle layer containing resin particles,
A model region forming step of ejecting a model material capable of absorbing energy into the particle layer to form a model region,
A support region forming step of ejecting a support material into the particle layer to form a support region,
An energy applying step of applying the energy to the model region to fuse the resin particles in the model region with each other and the resin particles in the model region and the resin particles in the support region in contact with the model region. When,
A method for manufacturing a three-dimensional model, which comprises. The 18th aspect of claim 18, wherein the support portion formed by solidifying the support material is removed by immersing the model portion formed by fusing the resin particles in the model region with an insoluble liquid. A method for manufacturing a three-dimensional model. The method for producing a three-dimensional model according to any one of claims 18 to 19, further comprising a preheating step of preheating the resin particles so that the temperature of the resin particles becomes a desired preheating temperature. The support material contains an adhesive component for adhering the resin particles to each other and a solvent.
The method for producing a three-dimensional model according to claim 20, wherein at least one of the melting point and the softening point of the adhesive component is higher than the preheating temperature and the boiling point of the solvent is lower than the preheating temperature. The method for producing a three-dimensional model according to any one of claims 18 to 21, wherein the thermal decomposition start temperature of the support portion formed by solidifying the support material is higher than the extrapolation melting end temperature of the resin particles. .. The method for manufacturing a three-dimensional model according to claim 22, wherein the thermal decomposition start temperature of the support portion is higher than 380 ° C. Any of claims 22 to 23, wherein the temperature of the model region when performing the energy application step is higher than the external melting end temperature of the resin particles and lower than the thermal decomposition start temperature of the support portion. The method for manufacturing a three-dimensional model according to. A three-dimensional modeling material set used in the three-dimensional modeling product manufacturing apparatus according to any one of claims 1 to 17 or the three-dimensional modeling material manufacturing method according to any one of claims 18 to 24.
It has the support material and the resin particles,
A material set for three-dimensional modeling, wherein the thermal decomposition start temperature of the support portion formed by solidifying the support material is higher than the extrapolation melting end temperature of the resin particles.