JP2021079605A - Apparatus for manufacturing three-dimensional molded article, method for manufacturing three-dimensional molded article, and program for manufacturing three-dimensional molded article - Google Patents

Abstract

To provide an apparatus for manufacturing a three-dimensional molded article, which can prevent generation of an impact noise caused by collision of flattening means to a molded layer made of a molding material after cured, a failure of the flattening means and damages in the molded article, and gives a three-dimensional molded article excellent in dimensional accuracy in a height direction, in a molding method by a system of molding a three-dimensional article by imparting the molding material in a layer state and stacking layers, preferably a material jetting system.SOLUTION: The apparatus for manufacturing a three-dimensional molded article has: discharge means for discharging a molding material; flattening means for flattening a surface of the discharged molding material; curing means for curing the flattened molding material; and control means for performing a control of adjusting a height of a region where a region with an increased height is expected to occur in which the height of the flattened molding material is higher than a target height.SELECTED DRAWING: Figure 4

Description

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

As a technique for modeling a three-dimensional three-dimensional object, a technique called additive manufacturing (AM; Adaptive Manufacturing) is known. This technique is a technique for forming a three-dimensional model by calculating a cross-sectional shape sliced thinly in the stacking direction, forming each layer according to the shape, and stacking the layers.

In recent years, among the above-mentioned additional manufacturing techniques, a material jetting (MJ) method for forming a three-dimensional model by laminating a curable resin has attracted attention. According to this material jetting method, when modeling a model portion that is the main body of a three-dimensional model, by modeling a support portion that supports the model portion, a shape that is difficult to model in principle (for example, an overhang portion). It is possible to model a shape having a shape, etc.).
As a conventional material jetting method, for example, by thinning out the discharge of the modeling material in some layers, contact of the flattening means is avoided in the layer above the thinned layer, and as a result, the flattening means is used. A three-dimensional modeling method for preventing roughening of the modeling surface due to the contact between the two has been proposed (see, for example, Patent Document 1).

In the present invention, in a method of applying a modeling material in layers and laminating the modeling material to form a three-dimensional model, preferably a material jetting method, a flattening means is provided on the modeling layer made of the cured modeling material. An object of the present invention is to provide a three-dimensional model manufacturing apparatus capable of preventing the generation of collision noise due to collision, failure of the flattening means, and damage to the model, and obtaining a three-dimensional model having excellent dimensional accuracy in the height direction. And.

The three-dimensional model manufacturing apparatus of the present invention as a means for achieving the above object is flattened by a discharge means for discharging a modeling material, a flattening means for flattening the surface of the discharged modeling material, and a flattening means. Control to adjust the height with respect to the curing means for curing the modeling material and the region where the height of the modeling material after flattening is expected to be higher than the target height. It has a control means to perform.

According to the present invention, in a method of applying a modeling material in layers and laminating the modeling material to form a three-dimensional model, preferably a modeling method by a material jetting method, a flattening means is applied to a modeling layer made of the cured modeling material. It is possible to provide a three-dimensional model manufacturing apparatus capable of preventing the generation of collision noise, failure of the flattening means, and damage of the modeled object due to the collision of the objects, and obtaining a three-dimensional modeled object having excellent dimensional accuracy in the height direction. it can.

FIG. 1 is a schematic view showing an example of the three-dimensional model manufacturing apparatus of the present invention. FIG. 2 is a block diagram showing an example of a control means of a three-dimensional model manufacturing apparatus. FIG. 3 is a schematic view showing an example of a three-dimensional model manufacturing apparatus used in the method for manufacturing a three-dimensional model of Comparative Example 1. FIG. 4 shows the modeling material after flattening of Comparative Example 1, FIG. 4A shows the modeling material in the state immediately after flattening, and FIG. 4B shows a height increase region after flattening and before curing. It is a schematic diagram which shows the modeling material in a state of being in a state. FIG. 5 is a graph showing the relationship between the thickness in the X direction and the height increment in the modeling material after flattening of Comparative Example 1. FIG. 6 is a flowchart showing an example of a processing procedure of a program for manufacturing a three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of Comparative Example 1. 7A and 7B show the modeling material after flattening of Examples 1 and 2, FIG. 7A shows the modeling material in the state immediately after flattening, and FIG. 7B shows the height increase region after flattening and before curing. It is a schematic diagram which shows the modeling material in the state where is not generated. FIG. 8 is a graph showing the relationship between the thickness in the X direction and the height increment in the shaped material after flattening of Examples 1 and 2. FIG. 9 is a flowchart showing an example of a processing procedure of a program for manufacturing a three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of the first embodiment. FIG. 10 is a flowchart showing an example of a processing procedure of a program for manufacturing a three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of the second embodiment.

(Three-dimensional model manufacturing equipment and three-dimensional model manufacturing method)
The three-dimensional model manufacturing apparatus of the present invention includes a discharge means for discharging a modeling material, a flattening means for flattening the surface of the discharged modeling material, and a curing means for curing the flattened modeling material. It also has a control means for controlling the height of a region where a height increase region where the height of the modeling material after flattening is predicted to be higher than the target height is expected to occur, and further. Have other means as needed.
In the present invention, the "height increase region" means a region in which an unintended increment occurs in the Z-axis direction with respect to the flattening plane when flattened by the flattening means. This increment is thought to be caused by, for example, surface tension. In general, such an increment becomes negligibly small as the width of the modeling region (width in the main scanning direction and / or width of the sub-scanning region) from which the modeling material is discharged is large, but is ignored as the width becomes smaller. It grows too big to be possible. The height increase region of the present invention specifically refers to a region in which the unintended increment becomes so large that it cannot be ignored.

The method for manufacturing a three-dimensional model of the present invention includes a discharge step of discharging a modeling material, a flattening step of flattening the surface of the discharged modeling material, and a curing step of curing the flattened modeling material. , Here, in the discharge step and / or the flattening step, with respect to a region where it is predicted that a height increase region in which the height of the modeling material after flattening is higher than the target height will occur. It is a method of performing height adjustment control for adjusting height, and may further include other steps as necessary.

The method for producing a three-dimensional object of the present invention can be suitably carried out by the three-dimensional object manufacturing apparatus of the present invention, the discharge step can be performed by a discharge means, and the flattening step can be performed by a flattening means. The curing step can be performed by the curing means, the height adjustment control can be performed by the control means, and the other steps can be performed by other means.

In the prior art, the molding material is not discharged in a specific layer to prevent the molding surface from being roughened due to the contact of the flattening means. However, since the collision amount differs depending on the line width, the adjustment for each layer is performed. The height of the flattening roller cannot be adjusted due to the line width, and the surface roughness deteriorates due to the flattening roller colliding with the surface of the modeled object, the surface accuracy deteriorates, and the flattening roller becomes There is a problem that it will be damaged.

In the present invention, even if a height increase region occurs in which the height of the modeling material after unintended flattening becomes higher than the target height due to the surface tension of the modeling material which is a liquid, the height of the modeling material after curing is used. By controlling to avoid collision between the modeling layer and the flattening means, collision noise is generated due to the collision of the flattening means with the modeling layer made of the cured modeling material, failure of the flattening means, and modeling. It is possible to prevent damage to an object and obtain a three-dimensional model with excellent dimensional accuracy in the height direction.
Here, the "target height" is sometimes referred to as a "target thickness", a "target height", or a "target thickness", and means a height (thickness) pre-designed based on modeling data.
The predetermined width in which the height increment and the height increase region can occur may be calculated from the surface tension of the modeling material having a predetermined composition, or the modeling material is actually discharged and flattened using a flattening roller. It may be calculated by measuring the height increment.

As a result of diligent studies, the present inventors have found that the height increase region in which the height of the modeling material after flattening becomes higher than the target height is caused by the surface tension of the modeling material which is a liquid. That is, FIG. 4 (A) is a schematic diagram showing a modeling material (model material) immediately after flattening, and FIG. 4 (B) is a schematic diagram showing a model material in a state where a height increase region is generated after flattening and before curing. FIG. 5 is a graph showing the relationship between the width t in the X direction and the height increment Δh in the modeling material (model material) after flattening. As shown in FIG. 5, the thickness t of the shaped material after flattening in the X direction has a peak at 0.8 mm, and is as high as 0.5% or more and 2.2% or less in the range of 0.5 mm to 1.2 mm. It was found to have an increment Δh.
Here, h represents the height (thickness) of one layer of the model material after flattening, and the particle size of the droplets of the model material is 50 μm. Height (thickness). Δh is the height increment of the model material after flattening, and is the ratio when the thickness of one layer of the model material after flattening is 100%.

Furthermore, as a result of diligent studies, the present inventors have found that in the flattened molding material whose width in the X direction is smaller than a predetermined width, a height increase region that is not negligible higher than the target height is generated. Was found. For example, in the case of a thin flattened modeling material having a thickness of 3 mm or less in the X direction (roller operating direction), the liquid modeling material is easily affected by surface tension and is several percent of the target height. It has the property of becoming tall and easy to get excited. When the edges of both ends of the flattened modeling material are close to each other, the edges at both ends are added up and a high swelling occurs. Further, the molding material is wound up at the final portion of leveling with the flattening roller in the X direction (flattening roller operating direction), so that a high swelling occurs especially at the end on the outlet side. The predetermined width may vary depending on the type and viscosity of the modeling material, but may be, for example, 3 mm or less, and can be appropriately calculated by a person skilled in the art by calculation or experiment.

In the present invention, the collision between the molding layer made of the molding material after curing and the flattening means caused by the occurrence of a height increase region in which the height of the molding material after flattening becomes higher than the target height is caused. Control to avoid. Specific methods for adjusting the height include (1) a method of reducing the discharge amount of the modeling material discharged to the height increasing region, and (2) a method of flattening the modeling material by a flattening means for flattening the height increasing region. It can be done by a method of increasing the scraping amount.

In the present invention, the "modeling material" means a material discharged from a discharge means in the production of a modeled object, and typically models a model material, an overhang portion, a detail portion, etc. for forming the three-dimensional modeled object itself. Examples include support materials used for this purpose. In the present invention, the modeling layer formed of the model material may be particularly referred to as a “model layer”, and the modeling layer formed of the support material may be particularly referred to as a “support layer”.

In one aspect of the present invention, when a height increase region occurs in which the height of the modeling material after flattening becomes higher than the target height, the discharge amount of the modeling material discharged to the height increase region is reduced. To do. By controlling to reduce the discharge amount of the modeling material discharged to the height increase region, the discharge amount of the modeling material to the height increase region is reduced, so that the surface tension of the modeling material causes an increase in the height direction. Can be prevented.
Here, the control for reducing the discharge amount of the modeling material is as follows: (1) The amount of the droplets discharged at one time is reduced (for example, the particle size of one drop of the modeling material is changed from a large diameter to a medium diameter to change the discharge amount. Examples include a method of (reducing), and (2) a method of providing a region in which the molding material is not discharged (thinning out the discharge, adjusting the thinning amount), and reducing the discharge amount of the entire discharge region.

In one aspect of the present invention, when a height increase region is generated in which the height of the modeling material after flattening is higher than the target height, the modeling material by the flattening means for flattening the height increase region is generated. Increase the amount of scraping. By controlling to increase the scraping amount of the modeling material by the flattening means for flattening the height increasing region, a large amount of the modeling material in the height increasing region is removed, so that the surface tension of the modeling material increases. It is possible to prevent the vertical increment from occurring.

As a method for increasing the scraping amount of the modeling material in such an embodiment, for example, when the flattening means is a flattening roller, the number of rotations of the flattening roller may be increased. By increasing the rotation speed of the flattening roller, which is a flattening means, the amount of scraping of the modeling material by the flattening roller can be increased, and the influence on the height of the surface tension can be reduced. Similarly, a flattening roller used only for flattening a region where a height increase region can occur is provided, and the surface roughness of the flattening roller is roughened to reduce the amount of scraping of the molding material by the flattening roller. It can be increased more than a normal roller, which can reduce the height increment.

In one aspect of the present invention, the height increasing regions are both ends in the main scanning direction of the shaped material after flattening. Due to the surface tension of the modeling material, the end (edge) of the three-dimensional model in the main scanning direction (X direction) tends to rise.

In one aspect of the present invention, it is used for modeling a modeling layer having a modeling region having a width in the main scanning direction of a predetermined width, for example, 3 mm or less. In the flattened modeling region where the width in the main scanning direction is a predetermined width, for example, 3 mm or less in the main scanning direction (X direction), both ends have the property of easily rising due to the influence of the surface tension of the liquid modeling material. Since the edges of the portions are close to each other, the bulges of the edges at both ends are added up, and a higher bulge is generated, a height increase region is likely to occur. Therefore, the manufacturing method of the present invention has a molding having such a thin molding region. It is suitably used for forming layers.

In one aspect of the present invention, the discharge means reciprocates in the main scanning direction, and the control means performs the control when the discharge means moves forward and backward, respectively. By performing the control at least at least during the forward movement and the reverse movement of the discharge means, the production efficiency is improved.

<Discharge process and discharge means>
The discharge step is a step of discharging the modeling material, and is carried out by the discharge means.
The discharge means is not particularly limited as long as it can discharge the modeling material, and can be appropriately selected depending on the intended purpose. Examples thereof include a discharge head.
The discharge head is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a piezoelectric element (piezo element) type head and a thermal expansion (thermal) type head. Among these, a piezoelectric element (piezo element) type head is preferable.

<< Modeling material >>
The modeling material is not particularly limited and can be appropriately selected based on the performance required for constructing the main body for modeling the three-dimensional modeled object (model portion). Examples thereof include a model material. When a support portion is used for shape support when modeling a three-dimensional modeled object, the modeling material also includes a support material for modeling the support portion.
The model material is a material for modeling a part constituting the model part.
In the present invention, the model portion means a portion constituting a main body for modeling a three-dimensional model, and is modeled by laminating model layers.

In the present invention, the support portion means a portion that holds a three-dimensional model in a predetermined position until the model portion solidifies, and is modeled by laminating support layers. The support portion means, for example, a portion that is arranged in a portion that supports the model portion in the direction of gravity, is in contact with the model portion, and supports the model portion from below. In the production of a three-dimensional model, the support portion is usually finally peeled off from the model portion, and only the model portion becomes a three-dimensional model.
In a preferred embodiment, the support material is a material (composition, concentration, etc.) different from that of the model material, and the cured product of the support material is more preferably easily peeled off from the model portion due to water solubility, deliquescent property, disintegration property, etc. It has properties.

The molding material is not particularly limited as long as it is a liquid material that is cured by applying energy such as light or heat, and can be appropriately selected depending on the intended purpose, but includes a polymerizable monomer and a polymerizable oligomer. , And other ingredients as needed. Among these, a material having liquid physical properties such as viscosity and surface tension that can be discharged by a modeling material discharge head used for a modeling material jet printer or the like is preferable.

-Polymerizable monomer-
Examples of the polymerizable monomer include a monofunctional monomer and a polyfunctional monomer. These may be used alone or in combination of two or more.

--Monofunctional monomer ---
Examples of the monofunctional monomer include acrylamide, N-substituted acrylamide derivative, N, N-di-substituted acrylamide derivative, N-substituted methacrylamide derivative, N, N-di-substituted methacrylamide derivative, acrylic acid and the like. These may be used alone or in combination of two or more. Among these, acrylamide, N, N-dimethylacrylamide, N-isopropylacrylamide, acryloylmorpholine, hydroxyethylacrylamide, and isobornyl (meth) acrylate are preferable.

The content of the monofunctional monomer is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 0.5% by mass or more and 90% by mass or less with respect to the total amount of the modeling material.

The monofunctional monomer other than the above is not particularly limited and may be appropriately selected depending on the intended purpose. For example, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, 2-hydroxypropyl (meth). ) Acrylate, caprolactone-modified tetrahydrofurfuryl (meth) acrylate, 3-methoxybutyl (meth) acrylate, tetrahydrofurfuryl (meth) acrylate, lauryl (meth) acrylate, 2-phenoxyethyl (meth) acrylate, isodecyl (meth) acrylate , Isooctyl (meth) acrylate, tridecyl (meth) acrylate, caprolactone (meth) acrylate, ethoxylated nonylphenol (meth) acrylate and the like. These may be used alone or in combination of two or more.

--Polyfunctional monomer ---
The polyfunctional monomer is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include bifunctional monomers and trifunctional or higher functional monomers. These may be used alone or in combination of two or more.

Examples of the bifunctional monomer include tripropylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, tetraethylene glycol di (meth) acrylate, polypropylene glycol di (meth) acrylate, and neopentyl glycol hydroxypivalic acid ester di. (Meta) acrylate, neopentyl glycol ester di (meth) acrylate of hydroxypivalate, 1,3-butanediol di (meth) acrylate, 1,4-butanediol di (meth) acrylate, 1,6-hexanediol di ( Meta) acrylate, 1,9-nonanediol di (meth) acrylate, diethylene glycol di (meth) acrylate, neopentyl glycol di (meth) acrylate, tripropylene glycol di (meth) acrylate, caprolactone-modified hydroxypivalate neopentyl glycol ester Examples thereof include di (meth) acrylate, propoxylated opentyl glycol di (meth) acrylate, ethoxy-modified bisphenol A di (meth) acrylate, polyethylene glycol 200 di (meth) acrylate, and polyethylene glycol 400 di (meth) acrylate. These may be used alone or in combination of two or more.

Examples of the trifunctional or higher monomer include trimethylolpropantri (meth) acrylate, pentaerythritol tri (meth) acrylate, dipentaerythritol hexa (meth) acrylate, triallyl isocyanurate, and ε-caprolactone-modified dipentaerythritol tri (meth). Meta) acrylate, ε-caprolactone-modified dipentaerythritol tetra (meth) acrylate, ε-caprolactone-modified dipentaerythritol penta (meth) acrylate, ε-caprolactone-modified dipentaerythritol hexa (meth) acrylate, tris (2-hydroxyethyl) Isocyanurate tri (meth) acrylate, ethoxylated trimethylol propantri (meth) acrylate, propoxylated trimethylol propanthroli (meth) acrylate, propoxylated glyceryl tri (meth) acrylate, pentaerythritol tetra (meth) acrylate, ditrimethylol propane. Examples thereof include tetra (meth) acrylate, dipentaerythritol hydroxypenta (meth) acrylate, ethoxylated pentaerythritol tetra (meth) acrylate, and penta (meth) acrylate ester. These may be used alone or in combination of two or more.

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

-Other ingredients-
The other components are not particularly limited and may be appropriately selected depending on the intended purpose. For example, a surfactant, a polymerization inhibitor, a polymerization initiator, a colorant, a viscosity modifier, an adhesive imparting agent, and an antioxidant. Examples include agents, antioxidants, cross-linking accelerators, UV absorbers, plasticizers, preservatives, dispersants and the like.

--Surfactant ---
Examples of the surfactant include a molecular weight of 200 or more and 5,000 or less, specifically, a PEG-type nonionic surfactant [an addition of 1 to 40 mol of ethylene oxide of nonylphenol (hereinafter abbreviated as “EO”). Stearate EO 1-40 mol additions, etc.], polyhydric alcohol-type nonionic surfactants (eg, sorbitan palmitate monoester, sorbitan stearate monoester, sorbitan stearate triester, etc.), fluorine-containing surfactant (eg For example, perfluoroalkyl EO 1 to 50 mol additions, perfluoroalkyl carboxylates, perfluoroalkyl betaines, etc.), modified silicone oils [eg, polyether-modified silicone oils, (meth) acrylate-modified silicone oils, etc.], etc. Can be mentioned. These may be used alone or in combination of two or more.
The content of the surfactant is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 3% by mass or less, preferably 0.1% by mass or more and 5% by mass or less, based on the total amount of the modeling material. Is more preferable.

--Polymerization inhibitor ---
Examples of the polymerization inhibitor include phenol compounds [hydroquinone, hydroquinone monomethyl ether, 2,6-di-t-butyl-p-cresol, 2,2-methylene-bis- (4-methyl-6-t-butylphenol)). , 1,1,3-Tris- (2-methyl-4-hydroxy-5-t-butylphenyl) butane, etc.], sulfur compounds [dilaurylthiodipropionate, etc.], phosphorus compounds [triphenylphosphite, etc.] , Amine compounds [phenothiazine, etc.] and the like. These may be used alone or in combination of two or more.
The content of the polymerization inhibitor is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 5% by mass or less, preferably 0.1% by mass or more and 5% by mass or less, based on the total amount of the modeling material. Is more preferable.

--Polymerization initiator ---
Examples of the polymerization initiator include a thermal polymerization initiator and a photopolymerization initiator. Among these, a photopolymerization initiator is preferable from the viewpoint of storage stability.
As the photopolymerization initiator, any substance that generates radicals by irradiation with light (particularly ultraviolet rays having a wavelength of 220 nm to 400 nm) can be used.
Examples of the photopolymerization initiator include acetophenone, 2,2-diethoxyacetophenone, p-dimethylaminoacetophenone, benzophenone, 2-chlorobenzophenone, p, p'-dichlorobenzophenone, p, p-bisdiethylaminobenzophenone, and Michler ketone. Benzyl, benzoin, benzoin methyl ether, benzoin ethyl ether, benzoin isopropyl ether, benzoin-n-propyl ether, benzoin isobutyl ether, benzoin-n-butyl ether, benzyl methyl ketal, thioxanthone, 2-chlorothioxanthone, 2-hydroxy-2- Methyl-1-phenyl-1-one, 1- (4-isopropylphenyl) 2-hydroxy-2-methylpropan-1-one, methylbenzoylformate, 1-hydroxycyclohexylphenylketone, azobisisobutyronitrile, Examples thereof include benzoyl peroxide and di-tert-butyl peroxide. These may be used alone or in combination of two or more.

The thermal polymerization initiator is not particularly limited and may be appropriately selected depending on the intended purpose. For example, an azo-based initiator, a peroxide initiator, a persulfate initiator, a redox (oxidation-reduction) initiator, etc. Can be mentioned.

Examples of the azo-based initiator include VA-044, VA-46B, V-50, VA-057, VA-061, VA-067, VA-086, 2,2'-azobis (4-methoxy-2, 4-Dimethylvaleronitrile) (VAZO 33), 2,2'-azobis (2-amidinopropane) dihydrochloride (VAZO 50), 2,2'-azobis (2,4-dimethylvaleronitrile) (VAZO 52) , 2,2'-azobis (isobutyronitrile) (VAZO 64), 2,2'-azobis-2-methylbutyronitrile (VAZO 67), 1,1-azobis (1-cyclohexanecarbonitrile) (VAZO) 88) (above, manufactured by DuPont Chemical), 2,2'-azobis (2-cyclopropylpropionitrile), 2,2'-azobis (methylisobutyrate) (V-601) (above, Wako Pure Chemical Industries, Ltd.) (Made by Co., Ltd.), etc.

Examples of the peroxide initiator include benzoyl peroxide, acetyl peroxide, lauroyl peroxide, decanoyl peroxide, disetylperoxydicarbonate, and di (4-t-butylcyclohexyl) peroxydicarbonate (trade name:). Perkadox 16S, manufactured by Akzo Nobel), di (2-ethylhexyl) peroxydicarbonate, t-butylperoxypivalate (trade name: Lupersol 11, manufactured by Elf Atochem), t-butylperoxy-2-ethylhexa Examples thereof include Noate (trade name: Trigonox 21-C50, manufactured by Akzo Nobel), dicumyl peroxide and the like.

Examples of the persulfate initiator include potassium persulfate, sodium persulfate, ammonium persulfate and the like.

Redox (oxidation-reduction) initiators include, for example, a combination of a persulfate initiator and a reducing agent such as sodium metabisulfite and sodium bisulfite, or a system based on an organic peroxide and a tertiary amine (eg,). , A system based on benzoyl peroxide and dimethylaniline), a system based on an organic hydroperoxide and a transition metal (for example, a system based on cumenehydroperoxide and cobalt naphthate), and the like.

The content of the polymerization initiator is not particularly limited and may be appropriately selected depending on the intended purpose, but is preferably 10% by mass or less, more preferably 5% by mass or less, based on the total amount of the modeling material.

--Colorant ---
As the colorant, dyes and pigments that are soluble or stably dispersed in the molding material and have excellent thermal stability are suitable. Among these, a soluble dye is preferable. Further, it is possible to mix two or more kinds of colorants in a timely manner by adjusting the color or the like.

<Curing process and curing means>
The curing step is a step of irradiating the active energy rays for curing the modeling material discharged in the discharging step, and is carried out by the curing means.
Examples of the active energy ray include ultraviolet rays, electron beams, α rays, β rays, γ rays, and X-rays. Among these, ultraviolet rays are preferable.
The curing means is not particularly limited as long as the discharged modeling material can be cured, and can be appropriately selected depending on the intended purpose. Examples thereof include an ultraviolet irradiation device.

Examples of the ultraviolet irradiation device include a light emitting diode (LED), a high-pressure mercury lamp, an ultra-high pressure mercury lamp, and a metal halide lamp. Among these, the LED is particularly preferable in that the irradiation intensity can be changed.
The high-pressure mercury lamp is a point light source, but the DeepUV type, which has high light utilization efficiency in combination with an optical system, can irradiate in a short wavelength region.
Metal halide is effective for colored substances because it has a wide wavelength range, and halides of metals such as Pb, Sn, and Fe are used and can be selected according to the absorption spectrum of the polymerization initiator. The lamp used for curing is not particularly limited and may be appropriately selected depending on the purpose. For example, commercially available lamps such as H lamp, D lamp, V lamp manufactured by Fusion Systems, etc. are also available. Can be used.

<Height adjustment control and control means>
In the present invention, the "control means" means a means for controlling the operation of a discharge means, a curing means, and other means (for example, a flattening means). A functional block diagram of the control means is shown in FIG. 2, and details of the control means will be described later based on an example of a specific embodiment. The control means may include storage means such as ROM and RAM and calculation means such as CPU and FPGA. The storage means may store a program for causing each means such as the discharge means and the curing means to perform a specific operation, and control the operation of each means based on the program.
In the present invention, when each means such as a discharge means and a hardening means is operated by a control means, when each means moves in a predetermined direction, the movement is relative to a modeling table (or a three-dimensional model). It means movement. Therefore, for example, in the case of "the ejection means moves in the main scanning direction", the ejection means itself may move in the main scanning direction, or the modeling table (or the three-dimensional model) moves in the main scanning direction. The ejection means may be controlled to move relatively in the main scanning direction.
The height adjustment control is applied to a region in which it is predicted that a height increase region in which the height of the modeling material after flattening becomes higher than the target height will occur in the discharge step and / or the flattening step. , It is a control for adjusting the height, and is implemented by the control means controlling the operation of each means.
By the action of the control means, it is possible to reduce the increase in the height direction of the modeling material, so that the flattening means may fail and the modeled object may be damaged due to the collision of the flattening means with the cured modeling material. A three-dimensional model that can be prevented and has excellent dimensional accuracy in the height direction can be obtained.

The storage means that can be included in the control means is not particularly limited and may be appropriately selected depending on the intended purpose. For example, in addition to a main storage device such as a RAM (Random Access Memory) and a ROM (Read Only Memory), Auxiliary storage devices such as HDD (Hard Disk Drive) and SDD (Solid State Drive) can also be mentioned.
The calculation means that can be included in the control means is not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a CPU (Central Processing Unit) and an FPGA (Field Programmable Gate Array).

<Other processes and other means>
The other steps are not particularly limited and may be appropriately selected depending on the intended purpose. Examples thereof include a flattening step and a drying step.
The other means are not particularly limited and may be appropriately selected depending on the intended purpose, and examples thereof include a flattening means, a drying means, and a stage.

-Flatration process and flattening means-
The flattening step is a step of flattening the modeling layer formed by the discharge step, and is carried out by the flattening means.
Examples of the flattening means include rollers, brushes, blades and the like.
When the flattening means flattens the modeling material, the accuracy and flatness of the average thickness of the modeling layer can be ensured.

-Stage-
The stage means a base on which modeling layers are laminated to form a three-dimensional model.
The stage may be movable by a motor or the like, or may be movable up and down. The "stage" may be referred to as a "modeling stage" or a "modeling table".
The shape of the stage is not particularly limited and may be appropriately selected depending on the intended purpose, but it is preferably flat.

Here, the three-dimensional model manufacturing apparatus of the present invention will be described in detail with reference to the drawings.
In each drawing, the same components may be designated by the same reference numerals, and duplicate description may be omitted. Further, the number, position, shape, etc. of the following constituent members are not limited to the present embodiment, and can be a preferable number, position, shape, etc. for carrying out the present invention.

FIG. 1 is a schematic view showing an example of the three-dimensional model manufacturing apparatus of the present invention. In the three-dimensional model manufacturing apparatus 10 of FIG. 1, the modeling layer 30 which is a layered model is laminated to form a three-dimensional model, and the stage 14 and the modeling layer 30 are sequentially laminated on the stage 14. It is equipped with a modeling unit 20 for modeling while.

The modeling unit 20 includes a first head 11 which is a discharge means for discharging a modeling material to a unit holder 21, a UV irradiation unit 13 for irradiating ultraviolet rays as active energy rays, and a flattening means for flattening the modeling layer 30. The flattening roller 16 is provided. It should be noted that not only the modeling material as a model material for modeling the three-dimensional modeled object but also the second head 12 for discharging the support material supporting the modeling of the three-dimensional modeled object can be provided.

Here, in the X direction, two second heads 12 are arranged with the first head 11 interposed therebetween, UV irradiation units 13 are arranged outside the two second heads 12, and further, outside the UV irradiation unit 13. A flattening roller 16 is arranged as a flattening member in each of the above.

The modeling material is supplied to the first head 11 via a supply tube or the like by a cartridge that is replaceably mounted on the cartridge mounting portion. When a modeling material having a color such as black, cyan, magenta, or yellow is used, a plurality of nozzle rows for ejecting droplets of each color can be arranged on the first head 11.

The UV irradiation unit 13 cures the modeling material discharged from the first head 11. When the UV irradiation unit 13 includes a support material, the UV irradiation unit 13 cures the modeling layer 30 made of the support material discharged from the second head 12.
Examples of the UV irradiation unit 13 include a light emitting diode (LED) and an ultraviolet irradiation lamp. When an ultraviolet irradiation lamp is used, it is preferable to provide a mechanism for removing ozone generated by ultraviolet irradiation.
Examples of the type of ultraviolet irradiation lamp include a high-pressure mercury lamp, an ultra-high pressure mercury lamp, and a metal halide lamp. Ultra-high pressure mercury lamps are point light sources, but ultraviolet irradiation lamps with high light utilization efficiency in combination with an optical system can irradiate in the short wavelength region. Since metal halide has a wide wavelength range, it is effective in curing colored substances. A halide of a metal such as Pb, Sn, or Fe is used and can be selected according to the absorption spectrum of the photopolymerization initiator.

The flattening roller 16 flattens the surface of the molding layer 30 cured on the stage 14 by relative movement with the stage 14 while being rotated.
The term "on the stage 14" means that the stage 14 and the modeling layer 30 to be laminated on the stage 14 are included unless otherwise specified.

The unit holder 21 of the modeling unit 20 is movably held by a guide member arranged in the X direction.
Further, on one side of the modeling unit 20 in the X direction, a maintenance mechanism for maintaining and recovering the first head 11 is arranged.

Further, the guide member holding the unit holder 21 of the modeling unit 20 is held by the side plates on both sides. The side plate has a slider portion movably held by a guide member arranged on the base member, and the modeling unit 20 can reciprocate in the Y direction orthogonal to the X direction.
The stage 14 is moved up and down in the Z direction by the raising and lowering means 15. The elevating means 15 is movably arranged on a guide member arranged in the X direction on the base member.

Next, an outline of the modeling operation by the three-dimensional model manufacturing apparatus 10 will be described with reference to FIG.
First, the modeling unit 20 is moved in the Y direction and positioned on the stage 14. Next, while moving the stage 14 with respect to the stopped modeling unit 20, the model material 301 is discharged from the first head 11 to the modeling region (region constituting the three-dimensional model). When a support material is used, the support material 302 is discharged from the second head 12 to a support area (area to be removed after modeling) other than the modeling area.

Next, the UV irradiation unit 13 irradiates the model material 301 and the support material 302 with ultraviolet rays to cure them, and forms a modeling layer 30 for one layer including the modeling object 17 made of the modeling material and the modeling object 18 made of the support material. To do.

The modeling layer 30 is repeatedly modeled and sequentially laminated to form a target three-dimensional model composed of the model material 301 while supporting the model material 301 with the support material 302. For example, in the example of FIG. 1, five layers of modeling layers 30A to 30E are laminated.

Here, every time a plurality of modeling layers 30 are laminated (it does not have to be a fixed value), for example, every 10 layers are laminated, the flattening roller 16 is pressed against the outermost modeling layer 30 to flatten it. This ensures the thickness accuracy and flatness of the modeling layer 30.
When a roller-shaped member such as the flattening roller 16 is used as the flattening means, the flattening effect is improved by rotating the flattening roller 16 in the direction opposite to the moving direction in the X direction. be able to.

Further, in order to keep the gap between the modeling unit 20 and the outermost modeling layer 30 constant, here, the stage 14 is lowered by the elevating means 15 every time one layer of the modeling layer 30 is formed. The modeling unit 20 may be raised and lowered.

The three-dimensional model manufacturing apparatus may include a collection member for the model material 301 and the support material 302, a recycling mechanism, and the like. Further, a discharge state detecting means for detecting the non-discharge nozzles of the first head 11 and the second head 12 may be provided. Further, the environmental temperature in the apparatus at the time of modeling may be controlled.

(Program for manufacturing 3D objects)
The program for manufacturing a three-dimensional model of the present invention is caused by a height increase region in which the height of the model material after flattening becomes higher than the target height, and is caused by a modeling layer made of the modeled material after curing and flattening. Have the computer perform a process to avoid conflict with the means.

When a height increase region occurs in which the height of the modeling material after flattening becomes higher than the target height, the computer is made to perform a process of reducing the discharge amount of the modeling material discharged to the height increase region. Is preferable.

When a height increase region occurs in which the height of the modeling material after flattening is higher than the target height, a treatment for increasing the scraping amount of the modeling material by the flattening means for flattening the height increase region. It is preferable to let the computer do the above.
In this case, it is preferable that the flattening means is a flattening roller and the rotation speed of the flattening roller is increased.

According to the three-dimensional model manufacturing program of the present invention, it is possible to prevent the generation of collision noise due to the collision of the flattening means with the modeling layer made of the cured modeling material, the failure of the flattening means, and the damage of the model. A three-dimensional model with excellent dimensional accuracy in the height direction can be obtained.

The program for manufacturing a three-dimensional model can cause a computer to perform other processes in addition to the above processes.
Other treatments include, for example, flattening the layer of the discharged modeling material, irradiating the discharged modeling material with active energy rays to cure it, cleaning the modeled object, and modeling. Examples include the process of drying the shaped object.

Since the program for manufacturing a three-dimensional model of the present invention is realized as the device for manufacturing a three-dimensional model of the present invention by using a computer or the like as a hardware resource, a preferred embodiment in the program for manufacturing a three-dimensional model of the present invention. Can be, for example, the same as the preferred embodiment in the three-dimensional model manufacturing apparatus of the present invention.

The program for manufacturing a three-dimensional object of the present invention can be created by using various known program languages according to the configuration of the computer system to be used, the type and version of the operating system, and the like.

The program for manufacturing a three-dimensional model of the present invention may be recorded on a recording medium such as an internal hard disk or an external hard disk, or may be recorded on a recording medium such as a CD-ROM, DVD-ROM, MO disk, or USB memory. You may leave it. These recording media may be storage means included in the control means.
Further, when the program for manufacturing a three-dimensional model of the present invention is recorded on the above-mentioned recording medium, it is used by installing it directly or on a hard disk through a recording medium reader of a computer system, if necessary. be able to. Further, the program for manufacturing a three-dimensional object of the present invention may be recorded in an external storage area (such as another computer) accessible from the computer system through the information communication network. In this case, the program for manufacturing a three-dimensional object of the present invention recorded in the external storage area can be used by installing it directly from the external storage area through the information communication network or by installing it on the hard disk, if necessary.
The program for manufacturing a three-dimensional model of the present invention may be divided and recorded on a plurality of recording media for each arbitrary process.

<Three-dimensional model manufacturing equipment>
The three-dimensional model manufacturing apparatus of the present invention is equipped with the program for manufacturing a three-dimensional model of the present invention.
The three-dimensional model manufacturing apparatus of the present invention is not particularly limited except that the program for manufacturing the three-dimensional model of the present invention is mounted, and other programs and the like can be mounted.

<Computer readable recording medium>
The computer-readable recording medium of the present invention comprises recording the program for manufacturing a three-dimensional object of the present invention.
The computer-readable recording medium in the present invention is not particularly limited and may be appropriately selected depending on the intended purpose. For example, an internal hard disk, an external hard disk, a CD-ROM, a DVD-ROM, a MO disk, or a USB. Memory etc. can be mentioned.
Further, the computer-readable recording medium in the present invention may be a plurality of recording media in which the active energy ray irradiation program for manufacturing a three-dimensional model of the present invention is divided and recorded for each arbitrary process.

The processing by the three-dimensional model manufacturing program of the present invention can be executed by using a computer having a control means constituting the three-dimensional model manufacturing apparatus of the present invention.
The computer is not particularly limited as long as it is a device equipped with devices such as storage, calculation, and control, and can be appropriately selected according to the purpose. Examples thereof include a personal computer.

Here, an outline of the control means of the three-dimensional model manufacturing apparatus will be described with reference to FIG. FIG. 2 is a block diagram of a control means of a three-dimensional model manufacturing apparatus.

The control means 500 includes a CPU 501 that controls the entire three-dimensional model manufacturing apparatus, a ROM 502 that stores the program for manufacturing the three-dimensional model of the present invention and other fixed data in the CPU 501, and a RAM 503 that temporarily stores the modeling data and the like. The main control unit 500A including the main control unit 500A is provided.
Further, the control means 500 includes a non-volatile memory (NVRAM) 504 for holding data even while the power supply of the device is cut off. Further, the control means 500 includes an ASIC 505 that processes an input / output signal for controlling the entire device and image processing that performs various signal processing on the image data.
Further, the control means 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 (section data) that is slice data obtained by slicing a modeled object (three-dimensional modeled object) in the final form for each modeling layer, and is an information processing device such as a personal computer. It is composed of.

The control means 500 includes an I / O 507 for capturing detection signals of various sensors.
Further, the control means 500 includes a head drive control unit 508 that drives and controls the first head 11 of the modeling unit 20, and a head drive control unit 509 that drives and controls the second head 12.
Further, the control means 500 includes a motor drive unit 510 that drives a motor constituting the unit X direction moving mechanism 550 that moves the modeling unit 20 in the X direction, and Y that moves the modeling unit 20 in the Y direction (sub-scanning direction). A motor drive unit 511 for driving a motor constituting the directional scanning mechanism 552 is provided.

The control means 500 constitutes a motor drive unit 513 that drives a motor constituting the stage X-direction scanning mechanism 553 that moves the stage 14 in the X direction together with the elevating means 15, and an elevating means 15 that moves the stage 14 up and down in the Z direction. It includes a motor drive unit 514 that drives the motor. As described above, the modeling unit 20 can be moved up and down in the Z direction.

The control means 500 includes a motor drive unit 516 that drives the motor 26 that rotationally drives the flattening roller 16, and a maintenance drive unit 518 that drives the maintenance mechanism 61 of the first head 11 and the second head 12.

The control means 500 includes a curing control unit 519 that controls ultraviolet irradiation by the UV irradiation unit 13.
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 means 500.
An operation panel 522 for inputting and displaying information necessary for this device is connected to the control means 500.
As described above, the control means 500 receives the modeling data from the modeling data creating device 600. The modeling data is data (data in the modeling area) that forms the model 17 in each model layer 30 as slice data obtained by slicing the shape of the target three-dimensional model.

The main control unit 500A creates data in which the data of the support area for adding the support material is added to the modeling data (modeling area data), and gives the data to the head drive control units 508 and 509. The head drive control units 508 and 509, respectively, discharge the droplets of the model material 301 from the first head 11 into the modeling region, and discharge the droplets of the liquid support material 302 from the second head 12 into the support region.
The manufacturing device is composed of the modeling data creating device 600 and the three-dimensional modeling object manufacturing device 10.

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

(Comparative Example 1)
The three-dimensional model manufacturing apparatus 200 used in Comparative Example 1 shown in FIG. 3 includes a modeling stage 111 on which the three-dimensional modeling object 110 is placed, and a modeling unit 120 that sequentially stacks the modeling objects 110 on the modeling stage 111. It has.

The modeling stage 111 is configured to be movable in the X direction, the Y direction, and the Z direction. The modeling unit 120 may be moved in the X direction. As a result, the outbound and inbound modeling operations can be realized.

The modeling unit 120 includes, as discharge means, a first head 121, which is a discharge means for discharging the model material 201, and a second head 122, which is a discharge means for discharging the support material 202.

The modeling unit 120 irradiates the flattening roller 123, which is a flattening means for flattening the discharged model material 201 and the support material 202, respectively, with ultraviolet rays as active energy rays to irradiate the model material 201 and the support material 202, respectively. It includes two UV irradiation units 124A and 124B to be cured.

Here, when the modeling stage 111 moves in the outward direction in the X direction, the flattening roller 123 is arranged on the upstream side of the first head 121, and the UV irradiation unit 124A is arranged on the upstream side of the flattening roller 123. .. Similarly, the second head 122 is arranged on the downstream side of the first head 121, and the UV irradiation unit 124B is arranged side by side on the downstream side of the second head 122.

Here, FIG. 6 is a flowchart showing an example of the processing flow of the discharge program for manufacturing the three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of Comparative Example 1. Hereinafter, the processing flow of the method for manufacturing the three-dimensional model of Comparative Example 1 will be described with reference to FIGS. 3, 4, and 5.

In step S1, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the model layer of the target shape shown in FIG. 4A, the process shifts to S2. Here, the model layer shown in FIG. 4A of Comparative Example 1 has a rectangular shape.

In step S2, based on the slice data of the model layer shown in FIG. 4 (A), the model material 201 is discharged from the first head 121 onto the stage 111 by the model scan 1 on the outbound route, and ultraviolet rays are irradiated from the UV irradiation unit 124A. And harden to form the model layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the model material 201 from the first head 121 onto the model layer 1 by the model scan 2 on the return route based on the slice data of the model layer shown in FIG. 4 (A). Then, flattening is performed by the flattening roller 123, and ultraviolet rays are irradiated from the UV irradiation unit 124B to cure the model layer 2, and the process shifts to S3.

In step S3, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S4 if it has the support layer, and shifts the process to S5 if it does not have the support layer.

In step S4, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the stage 111 by the support scan 1 on the outbound route, irradiates the UV irradiation unit 124A with ultraviolet rays, and cures the support material 202. Form layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route, flattens by the flattening roller 123, and UV irradiation unit 124B. When the support layer 2 is formed by irradiating with ultraviolet rays and curing the support layer 2, the process shifts to S5.

In step S5, when the control means of the three-dimensional model manufacturing apparatus 200 raises the modeling unit 120 by a predetermined amount in the Z direction, this process ends. After that, by repeating the series of processes from step S1 to step S5 a predetermined number of times as needed, the three-dimensional model of Comparative Example 1 can be obtained.

In Comparative Example 1, FIG. 4 (A) shows the model material 102 immediately after flattening, and FIG. 4 (B) shows the both ends of the model material 102 after flattening and before curing to raise a height increase region 102a. Indicates the state. FIG. 101 in FIG. 4B is a flattening roller as a flattening means.
FIG. 5 is a graph showing the relationship between the thickness t in the X direction and the height increment Δh in the model material after flattening of Comparative Example 1, and the thickness t in the X direction of the model layer is increased in height to 0.8 mm. It was found that the height increment of 0.5% or more and 2.2% or less occurs in the range where the thickness t in the X direction has a peak and is 0.5 mm to 1.2 mm.

(Example 1)
In Example 1, the model layer having the shape shown in FIG. 7 was formed by using the three-dimensional model manufacturing apparatus 200 shown in FIG. 3 in the same manner as in Comparative Example 1.

Here, FIG. 9 is a flowchart showing an example of the processing flow of the program for manufacturing the three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of the first embodiment. Hereinafter, the processing flow of the method for manufacturing the three-dimensional model of the first embodiment will be described with reference to FIGS. 3, 7, and 8.

In step S11, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the model layer of the target shape shown in FIG. 7A, the process shifts to S12. Here, the model layer shown in FIG. 7A of Example 1 has a rectangular shape.

In step S12, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the height increase region, and if it has the height increase region, the process shifts to S13 and has the height increase region. If not, the process shifts to S14. Here, the height increase region is flattened in advance by using a molding material having a predetermined composition (surface tension) and a height increment due to the discharge characteristics of the discharge head, and actually discharging the molding material and using a flattening roller. It can be obtained in consideration of the height increment caused by the change.

In step S13, the control means of the three-dimensional model manufacturing apparatus 200 reduces the discharge amount of the model material to be discharged to the height increase region based on the slice data of the model layer shown in FIG. 7 (A), and on the outward route. The model material 201 is discharged from the first head 121 onto the stage 111 by the model scan 1, and the model layer 1 is formed by irradiating the UV irradiation unit 124A with ultraviolet rays and curing the model material 201. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 reduces the discharge amount of the model material discharged to the height increase region based on the slice data of the model layer shown in FIG. 7 (A), and performs a model scan on the return route. When the model material 201 is discharged from the first head 121 onto the model layer 1 by 2, the model material 201 is flattened by the flattening roller 123, and the UV irradiation unit 124B is irradiated with ultraviolet rays to cure the model layer 2, the process is performed. Move to S15.
The discharge amount of the model material to be discharged to the height increase region can be reduced by reducing the discharge amount of the model material or by thinning out the discharge of the model material by a predetermined thinning amount.

In step S14, the control means of the three-dimensional model manufacturing apparatus 200 transfers the model material 201 from the first head 121 onto the stage 111 by the model scan 3 on the outbound route based on the slice data of the model layer shown in FIG. 7 (A). The model layer 3 is formed by discharging and irradiating ultraviolet rays from the UV irradiation unit 124A to cure the model layer 3. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the model material 201 from the first head 121 onto the model layer 3 by the model scan 4 on the return route based on the slice data of the model layer shown in FIG. 7 (A). Then, flattening is performed by the flattening roller 123, and ultraviolet rays are irradiated from the UV irradiation unit 124B to cure the model layer 4, and the process shifts to S15.

In step S15, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S16 if it has the support layer, and shifts the process to S17 if it does not have the support layer.

In step S16, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the stage 111 by the support scan 1 on the outbound route, irradiates the UV irradiation unit 124A with ultraviolet rays, and cures the support material 202. Form layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route, flattens by the flattening roller 123, and UV irradiation unit 124B. When the support layer 2 is formed by irradiating with ultraviolet rays and curing the support layer 2, the process shifts to S17.

In step S17, when the control means of the three-dimensional model manufacturing apparatus 200 raises the modeling unit 120 by a predetermined amount in the Z direction, this process ends. After that, the three-dimensional model of Example 1 can be obtained by repeating the series of processes from step S11 to step S17 a predetermined number of times as needed.

In Example 1, FIG. 7A is a schematic view showing a model material 102 in a state immediately after flattening, and FIG. 7B is a schematic view showing a model material 102 in a state in which a height increase region does not occur after flattening and before curing. Yes, the height increase region does not occur in the model material after flattening in Example 1. In FIG. 7B, 101 is a flattening roller as a flattening means.
FIG. 8 shows the relationship between the thickness h in the X direction and the height increment Δh in the model material after flattening of Example 1, where the dotted line is Comparative Example 1 and the solid line is Example 1. In Example 1, since the height increase region of the model material after flattening does not occur, the peak of height increment as in Comparative Example 1 does not occur.
In the first embodiment, by controlling to reduce the discharge amount of the model material discharged to the height increase region, it is possible to prevent the height increase region from being generated due to the surface tension of the model material, and the model material is made of the cured model material. It is possible to prevent the generation of collision noise due to the collision of the flattening means with the model layer, the failure of the flattening means, and the damage of the modeled object, and it is possible to obtain a three-dimensional modeled object having excellent dimensional accuracy in the height direction.

(Example 2)
In Example 2, the model layer having the shape shown in FIG. 7 was formed by using the three-dimensional model manufacturing apparatus 200 shown in FIG. 3 in the same manner as in Comparative Example 1.

Here, FIG. 10 is a flowchart showing an example of the processing flow of the program for manufacturing the three-dimensional model in the control means of the three-dimensional model manufacturing apparatus of the second embodiment. Hereinafter, the processing flow of the method for manufacturing the three-dimensional model of the second embodiment will be described with reference to FIGS. 3, 7, and 8.

In step S21, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the model layer of the target shape shown in FIG. 7A, the process shifts to S22. Here, the three-dimensional model shown in FIG. 7A of Example 2 has a rectangular shape.

In step S22, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the height increase region, and if it has the height increase region, the process shifts to S23 and has the height increase region. If not, the process shifts to S24. Here, the height increase region is flattened in advance by using a molding material having a predetermined composition (surface tension) and a height increment due to the discharge characteristics of the discharge head, and actually discharging the molding material and using a flattening roller. It can be obtained in consideration of the height increment caused by the change.

In step S23, the control means of the three-dimensional model manufacturing apparatus 200 transfers the model material 201 from the first head 121 onto the stage 111 by the model scan 1 on the outbound route based on the slice data of the model layer shown in FIG. 7 (A). The model layer 1 is formed by discharging and irradiating ultraviolet rays from the UV irradiation unit 124A to cure the data. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 scrapes the model material based on the slice data of the model layer shown in FIG. 7A and increases the number of rotations of the flattening roller in the height increase region. The amount is increased, the model material 201 is discharged from the first head 121 onto the model layer 1 by the model scan 2 on the return route, flattened by the flattening roller 123, and cured by irradiating ultraviolet rays from the UV irradiation unit 124B. When the model layer 2 is formed, the process shifts to S25.

In step S24, the control means of the three-dimensional model manufacturing apparatus 200 transfers the model material 201 from the first head 121 onto the stage 111 by the model scan 3 on the outbound route based on the slice data of the model layer shown in FIG. 7 (A). The model layer 3 is formed by discharging and irradiating ultraviolet rays from the UV irradiation unit 124A to cure the data. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the model material 201 from the first head 121 onto the model layer 3 by the model scan 4 on the return route based on the slice data of the model layer shown in FIG. 7 (A). Then, flattening is performed by the flattening roller 123, and ultraviolet rays are irradiated from the UV irradiation unit 124B to cure the model layer 4, and the process shifts to S25.

In step S25, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S26 if it has the support layer, and shifts the process to S27 if it does not have the support layer.

In step S26, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the stage 111 by the support scan 1 on the outbound route, irradiates the UV irradiation unit 124A with ultraviolet rays, and cures the support material 202. Form layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 discharges the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route, flattens by the flattening roller 123, and UV irradiation unit 124B. When the support layer 2 is formed by irradiating with ultraviolet rays and curing the support layer 2, the process shifts to S27.

In step S27, when the control means of the three-dimensional model manufacturing apparatus 200 raises the modeling unit 120 by a predetermined amount in the Z direction, this process ends. After that, the three-dimensional model of Example 2 can be obtained by repeating the series of processes from step S21 to step S27 a predetermined number of times as needed.

In Example 2, FIG. 7A is a schematic view showing a model material 102 in a state immediately after flattening, and FIG. 7B is a schematic view showing a model material 102 in a state in which a height increase region does not occur after flattening and before curing. Yes, the height increase region does not occur in the model material after flattening in Example 2. FIG. 101 in FIG. 7B is a flattening roller as a flattening means.
FIG. 8 shows the relationship between the thickness h in the X direction and the height increment Δh in the model material after flattening of Example 2, where the dotted line is Comparative Example 1 and the solid line is Example 2. In Example 2, since the height increase region of the model material after flattening does not occur, the peak of height increment as in Comparative Example 1 does not occur.
In the second embodiment, by controlling to increase the scraping amount by the flattening roller in the height increase region, it is possible to prevent the height increase region from being generated due to the surface tension of the model material, and the model material is made of the cured model material. It is possible to prevent the generation of collision noise due to the collision of the flattening means with the model layer, the failure of the flattening means, and the damage of the modeled object, and a three-dimensional modeled object having excellent dimensional accuracy in the height direction can be obtained.

Examples of aspects of the present invention are as follows.
<1> Discharging means for discharging the modeling material and
A flattening means for flattening the surface of the discharged modeling material, and
A curing means for curing the flattened modeling material, and
A control means for controlling the height of a region where a height increase region where the height of the modeling material after flattening is expected to be higher than the target height is expected to occur, and a control means for adjusting the height.
It is a three-dimensional model manufacturing apparatus characterized by having.
<2> When a height increase region occurs in which the height of the modeling material after flattening becomes higher than the target height, the discharge amount of the modeling material discharged to the height increase region is reduced. > Is the three-dimensional model manufacturing apparatus.
<3> When a height increase region in which the height of the modeling material after flattening becomes higher than the target height occurs, the amount of scraping of the modeling material by the flattening means for flattening the height increase region. The three-dimensional model manufacturing apparatus according to <1>.
<4> The three-dimensional model manufacturing apparatus according to <3>, wherein the flattening means is a flattening roller, and the number of rotations of the flattening roller is increased.
<5> The three-dimensional model manufacturing apparatus according to any one of <1> to <4>, wherein the height increase region is both ends in the main scanning direction of the modeled material after flattening.
<6> The three-dimensional model manufacturing apparatus according to any one of <1> to <5>, which is used for modeling a modeling layer made of a modeling material having a thickness of 3 mm or less in the main scanning direction.
<7> The discharge means reciprocates in the main scanning direction, and the discharge means reciprocates.
The three-dimensional model manufacturing apparatus according to any one of <1> to <6>, wherein the control means performs the control when the discharge means moves forward and backward.
<8> The feature is that the computer is made to perform a process of adjusting the height in a region where a height increase region where the height of the modeling material after flattening is predicted to be higher than the target height is expected to occur. This is a program for manufacturing three-dimensional objects.
<9> The three-dimensional model manufacturing apparatus, which is equipped with the program for manufacturing the three-dimensional model according to the above <8>.
<10> Discharging process for discharging the modeling material and
A flattening step for flattening the surface of the discharged modeling material, and
A method for manufacturing a three-dimensional model including a curing step of curing the flattened modeling material.
In the discharge step and / or the flattening step, the height is adjusted with respect to a region where it is predicted that a height increase region in which the height of the modeling material after flattening is higher than the target height will occur. This is a method for manufacturing a three-dimensional model, which is characterized by performing height adjustment control.

The three-dimensional model manufacturing apparatus according to any one of <1> to <7> and <9>, the three-dimensional model manufacturing program according to <8>, and the three-dimensional model according to <10>. According to the manufacturing method, various problems in the prior art can be solved and the object of the present invention can be achieved.

121 1st head 122 2nd head 124A, 124B UV irradiation unit 111 Stage 123 Flattening roller 120 Modeling unit 200 Three-dimensional model manufacturing equipment

Japanese Unexamined Patent Publication No. 2019-123232

Claims (10)

Discharge means for discharging modeling materials and
A flattening means for flattening the surface of the discharged modeling material, and
A curing means for curing the flattened modeling material, and
A control means for controlling the height of a region where a height increase region where the height of the modeling material after flattening is expected to be higher than the target height is expected to occur, and a control means for adjusting the height.
A three-dimensional model manufacturing apparatus characterized by having. The first aspect of claim 1 is to reduce the discharge amount of the modeling material discharged to the height increasing region when a height increase region occurs in which the height of the modeling material after flattening becomes higher than the target height. Three-dimensional model manufacturing equipment. When a height increase region occurs in which the height of the modeling material after flattening becomes higher than the target height, the amount of scraping of the modeling material by the flattening means for flattening the height increase region is increased. The three-dimensional model manufacturing apparatus according to claim 1. The three-dimensional model manufacturing apparatus according to claim 3, wherein the flattening means is a flattening roller, and the number of rotations of the flattening roller is increased. The three-dimensional model manufacturing apparatus according to any one of claims 1 to 4, wherein the height increasing region is both ends in the main scanning direction of the modeling material after flattening. The three-dimensional model manufacturing apparatus according to any one of claims 1 to 5, which is used for modeling a modeling layer made of a modeling material having a thickness of 3 mm or less in the main scanning direction. The discharge means reciprocates in the main scanning direction,
The three-dimensional model manufacturing apparatus according to any one of claims 1 to 6, wherein the control means performs the control when the discharge means moves forward and backward. Three-dimensional modeling characterized by having a computer perform a process of adjusting the height of a region where a height increase region where the height of the modeling material after flattening is expected to be higher than the target height is expected to occur. Product manufacturing program. A three-dimensional model manufacturing apparatus comprising the program for manufacturing a three-dimensional model according to claim 8. The discharge process that discharges the modeling material and
A flattening step for flattening the surface of the discharged modeling material, and
A method for manufacturing a three-dimensional model including a curing step of curing the flattened modeling material.
In the discharge step and / or the flattening step, the height is adjusted with respect to a region where it is predicted that a height increase region in which the height of the modeling material after flattening is higher than the target height will occur. A method for manufacturing a three-dimensional model, which is characterized by performing height adjustment control.

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