JP2021079606A - 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 a method and an apparatus for manufacturing a three-dimensional molded article, which can prevent surface roughening caused by deposition of a support material on a side face of a modeled part due to chipping and scattering of the support material at a corner of a support extension part, in a molding method by a system of molding a three-dimensional article by imparting a molding material in a layer state and stacking layers, preferably a material jetting system.SOLUTION: The method for manufacturing a three-dimensional molded article includes: a discharge step of discharging a model material and a support material; a flattening step of flattening surfaces of the discharged model material and support material; and a curing step of curing the flattened model material and support material. A support extension part made of the support material is formed in such a manner that the width in a sub-scanning direction is gradually increased or decreased along a main scanning direction.SELECTED DRAWING: Figure 6

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.).
In such a material jetting method, in order to sharpen the end of the protruding portion protruding from the model portion, for example, a method of manufacturing a three-dimensional model in which a support expanding portion extended from the model portion is provided has been proposed ( For example, see 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, the support material is torn and scattered at the corners of the support expansion portion. It is an object of the present invention to provide a three-dimensional model manufacturing apparatus capable of preventing color mixing and surface roughness due to adhesion of a support material to the side surface of the model portion.

The method for manufacturing a three-dimensional model of the present invention as a means for achieving the above object is a discharge step of discharging a model material and a support material, and a flatness for flattening the surfaces of the discharged model material and the support material. The width of the support expansion portion made of the support material gradually increases or gradually increases toward the main scanning direction, which includes a forming step and a curing step of curing the flattened model material and the support material. It is formed so as to have a gradually decreasing shape.

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 material jetting method, the support material is torn and scattered at the corners of the support expansion portion. This makes it possible to provide a three-dimensional model manufacturing apparatus capable of preventing color mixing and surface roughness due to the support material adhering to the side surface of the model portion.

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. 4A and 4B show a three-dimensional model formed in Comparative Example 1, FIG. 4A is a top view, FIG. 4B is a front view, and FIG. 4C is a side view. FIG. 5 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. 6A and 6B show a three-dimensional model formed in the first embodiment, FIG. 6A is a top view, FIG. 6B is a front view, and FIG. 6C is a side view. FIG. 7 is a diagram illustrating C chamfering (C2). FIG. 8 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. 9A is a diagram showing an example of the three-dimensional model obtained in Comparative Example 1. FIG. 9B is a diagram showing an example of the three-dimensional model obtained in Example 1. 10A and 10B show a three-dimensional model formed in the second embodiment, FIG. 10A is a top view, FIG. 10B is a front view, and FIG. 10C is a side view. FIG. 11 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. 12A and 12B show a three-dimensional model formed in Example 3, FIG. 12A is a top view, FIG. 12B is a front view, and FIG. 12C is a side view. FIG. 13 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 third embodiment.

(Manufacturing method of three-dimensional model)
The method for manufacturing a three-dimensional model of the present invention includes a discharge step of discharging a model material and a support material, a flattening step of flattening the surface of the discharged model material and the support material, and the flattened model. The support expansion portion made of the support material includes a curing step of curing the material and the support material, and is formed so that the width in the sub-scanning direction gradually increases or decreases toward the main scanning direction. .. The method for producing a three-dimensional model further includes other steps as necessary.
In the present invention, the "support extension portion" is the vertical portion in order to prevent the modeling accuracy from being lowered due to the impact deviation of the model material, dripping, etc. when modeling a vertical wall surface or an overhang shape of a three-dimensional model. It means a support portion arranged adjacent to a wall surface or the overhang shape.

In the prior art, when a support expansion portion made of a support material is flattened by using a flattening roller, which is a flattening means, the support material is torn off at the corner portion of the support expansion portion, and the surrounding area is rounded. There is a problem that it scatters and adheres to the side surface of the three-dimensional modeled object, causing color mixing and surface roughness.
This is because the support material is a water-soluble modeling material, so the acute-angled corners of the support expansion portion are gradually dissolved by the moisture in the air, and the strength is weakened. When the support expansion part with weakened strength is flattened with a flattening roller, the corners of the support expansion part are torn, and the torn support material is scattered around and adheres to the side surface of the model part, resulting in color mixing and color mixing. Problems such as rough surface will occur.

In the present invention, the width of the support expansion portion in the sub-scanning direction gradually increases or decreases toward the main scanning direction, and particularly gradually decreases toward the progress direction of flattening by the flattening means. By forming, the sharp corners of the support expansion portion can be eliminated, and even if flattening is performed by the flattening roller, the corner portions of the support expansion portion are torn, and the torn support material is scattered around. It adheres to the side surface of the model part, and color mixing and surface roughness do not occur.
The shape of the corner portion of the support extension portion may be any of a C chamfer shape, an R chamfer shape, and a composite chamfer that is a combination of the C chamfer shape and the R chamfer shape, and faces the end portion of the support expansion portion. The structure may be gradually reduced to a staircase shape.

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, the corners of the support extension are formed so as to have a C-chamfered shape. By controlling the corners of the support expansion portion to have a C chamfer shape, the contact area of the flattening rollers at the corners of the support expansion portion is reduced, and the support material is suppressed from scattering due to scraping of the flattening rollers. can do.
The C-chamfered shape means a chamfered shape in which the surface formed by the C-chamfer is a flat surface or a substantially flat surface, and as shown in FIG. 7, "C2" means a corner having a side length of 2 mm. It means to cut out with a right-angled isosceles triangle. It is indicated by C only when the chamfer angle is 45 °.

In one aspect of the present invention, the corners of the support extension portion are formed so as to have an R chamfered shape. By controlling the corners of the support expansion portion to have an R chamfer shape, the contact area of the flattening rollers at the corners of the support expansion portion is reduced, and scattering of the support material due to scraping of the flattening rollers is suppressed. can do.
The R chamfered shape is a chamfered shape in which the surface formed by the chamfer is a curved surface.

In one aspect of the present invention, the support material is a water-soluble modeling material. Since the support material is water-soluble, the support portion formed by the support material can be easily removed with water after the molding is completed.
Here, "the support material is water-soluble" means that 100 g or more of the support material is dissolved in 1000 mL of water at 25 ° C. Whether or not the support material is dissolved can be determined by whether or not the water is transparent, and can be visually confirmed.

<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.

<Control means>
In the present invention, "control means" means means for controlling the operation of discharge means, curing means, and other means (for example, 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 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>
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.

− Flattening process−
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 used in 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 a three-dimensional model manufacturing apparatus used in 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 causes a computer to perform a process in which the width of the support expansion portion in the sub-scanning direction is formed so as to have a shape that gradually increases or decreases toward the main scanning direction.
It is preferable to let the computer perform a process of forming the corner portion of the support extension portion into a C-chamfered shape.
It is preferable to let the computer perform a process of forming the corner portion of the support extension portion into an R chamfered shape.
According to the program for manufacturing a three-dimensional model of the present invention, it is possible to prevent color mixing and surface roughness due to the support material adhering to the side surface of the model portion due to the support material being torn and scattered at the corners of the support expansion portion.

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 a first head 121 as a discharge means for discharging the model material 201 and a second head 122 as 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. 5 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 device for manufacturing the three-dimensional model 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 and 4.

In step S1, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the three-dimensional model of the target shape shown in FIG. 4, the process shifts to S2.
Here, as shown in FIGS. 4A to 4C, the three-dimensional model shown in FIG. 4 of Comparative Example 1 has an opening H in the center of the model portion, and the upper portion of the opening H. A support material is arranged in the opening H so that the shape can be formed.
When the support portion made of the support material has the same shape as the opening H, the support function cannot be fulfilled at the end portion of the support portion, and the lower sagging of the model portion occurs.
Therefore, in order to suppress the lower sagging of the model portion, as shown in FIG. 4A, a support expansion portion in which the support portion made of the support material is expanded in the X direction and the Y direction is formed.

In step S2, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the model layer, shifts the process to S3 if it has the model layer, and shifts the process to S4 if it does not have the model layer.

In step S3, the control means of the three-dimensional model manufacturing apparatus 200 is based on the slice data of the model layer of the three-dimensional model shown in FIG. 4, and the model scan 1 is performed on the outbound route from the first head 121 to the model material 201 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers 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 of the three-dimensional model shown in FIG. When the model layer 2 is formed by discharging, flattening by the flattening roller 123, and irradiating ultraviolet rays from the UV irradiation unit 124B to cure the model layer 2, the process shifts to S4.

In step S4, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S5 if it has the support layer, and shifts the process to S6 if it does not have the support layer.

In step S5, the control means of the three-dimensional model manufacturing apparatus 200 uses the slice data of the support layer of the three-dimensional model shown in FIG. 4 to perform the support scan 1 on the outbound route from the second head 122 to the support material 202 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the support layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route based on the slice data of the support layer of the three-dimensional model shown in FIG. When the support layer 2 is formed by discharging and flattening the data by the flattening roller 123 and irradiating the UV irradiation unit 124B with ultraviolet rays to cure the data, the process shifts to S6.

In step S6, 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 S6 a predetermined number of times, the three-dimensional model of Comparative Example 1 having the shape shown in FIG. 4 can be obtained.

In Comparative Example 1, as shown in FIG. 4A, the support function of the model unit can be stably fulfilled by expanding the support unit in the X direction and the Y direction to form the support expansion unit.
However, as shown in FIG. 4A, in Comparative Example 1, since the corner portion of the support expansion portion has an acute angle and the support material is a water-soluble modeling material, the corner portion of the support expansion portion is in the air. It is gradually dissolved by water and weakens in strength. When the corners of the support expansion part, which has become weaker, are scraped off with a flattening roller, which is a flattening means, the support material is torn and scattered, causing surface roughness due to the support material adhering to the side surface of the three-dimensional model. Color mixing will occur.

(Example 1)
In Example 1, the three-dimensional modeled object shown in FIG. 6 was modeled using the three-dimensional modeled object manufacturing apparatus 200 shown in FIG. 3 in the same manner as in Comparative Example 1.

Here, FIG. 8 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 and 6.

In step S11, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the three-dimensional model having the target shape shown in FIG. 6, the process shifts to S12.
Here, as shown in FIG. 6A, the three-dimensional model of Example 1 has a shape in which the corner portion of the support expansion portion is C-chamfered with respect to the three-dimensional model of FIG. 4 of Comparative Example 1. It was shaped like this.
As shown in FIGS. 6A to 6C, the support material is expanded in the X direction and the Y direction, and the corner portion of the support expansion portion is chamfered by C. Therefore, there are no sharp corners in the support extension.

In step S12, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the model layer, shifts the process to S13 if it has the model layer, and shifts the process to S14 if it does not have the model layer.

In step S13, the control means of the three-dimensional model manufacturing apparatus 200 is based on the slice data of the model layer of the three-dimensional model shown in FIG. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers 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 of the three-dimensional model shown in FIG. When the model layer 2 is formed by discharging, flattening by the flattening roller 123, and irradiating ultraviolet rays from the UV irradiation unit 124B to cure the model layer 2, the process shifts to S14.

In step S14, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S15 if it has the support layer, and shifts the process to S16 if it does not have the support layer.

In step S15, the control means of the three-dimensional model manufacturing apparatus 200 uses the slice data of the support layer of the three-dimensional model shown in FIG. 6 to perform the support scan 1 on the outbound route from the second head 122 to the support material 202 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the support layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route based on the slice data of the support layer of the three-dimensional model shown in FIG. When the support layer 2 is formed by discharging and flattening the data by the flattening roller 123 and irradiating the UV irradiation unit 124B with ultraviolet rays to cure the data, the process shifts to S16.

In step S16, 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 S11 to step S16 a predetermined number of times, the three-dimensional model of Example 1 shown in FIG. 6 can be obtained.

In the first embodiment, since the corner portion of the support expansion portion is shaped so as to have a C-chamfered shape, the support material is torn off at the corner portion of the support expansion portion and scattered, so that the support material is attached to the side surface of the model portion. It is possible to prevent color mixing and chamfering due to adhesion.

Here, FIG. 9A shows the three-dimensional model obtained by the method for producing the three-dimensional model of Comparative Example 1, and FIG. 9B shows the three-dimensional model obtained by the method for producing the three-dimensional model of Example 1.
In Comparative Example 1 of FIG. 9A, the support material is torn at the corner portion of the support expansion portion, and the torn support material is scattered in one direction, resulting in surface roughness due to the support material adhering to the side surface of the model portion. You can see that there is. On the other hand, in the first embodiment of FIG. 9B, since the corner portion of the support expansion portion is C-chamfered and there is no acute-angled corner portion, there is no adhesion or color mixing of the support material on the side surface of the model portion, and a beautiful modeled object can be obtained. Was done.

(Example 2)
In Example 2, the three-dimensional modeled object shown in FIG. 10 was modeled using the three-dimensional modeled object manufacturing apparatus 200 shown in FIG. 3 in the same manner as in Comparative Example 1.

Here, FIG. 11 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 and 10.

In step S21, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the three-dimensional model of the target shape shown in FIG. 10, the process shifts to S22.
Here, as shown in FIG. 10A, the three-dimensional model of Example 2 has a shape in which the corner portion of the support expansion portion is R-chamfered with respect to the three-dimensional model of FIG. 4 of Comparative Example 1. It was shaped like this.
As shown in FIGS. 10A to 10C, the support material is expanded in the X and Y directions, and the corners of the expanded support expansion portion are chamfered by R. Therefore, there are no sharp corners in the support extension.

In step S22, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the model layer, shifts the process to S23 if it has the model layer, and shifts the process to S24 if it does not have the model layer.

In step S23, the control means of the three-dimensional model manufacturing apparatus 200 is based on the slice data of the model layer of the three-dimensional model shown in FIG. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers 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 of the three-dimensional model shown in FIG. When the model layer 2 is formed by discharging, flattening by the flattening roller 123, and irradiating ultraviolet rays from the UV irradiation unit 124B to cure the model layer 2, the process shifts to S24.

In step S24, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S25 if it has the support layer, and shifts the process to S26 if it does not have the support layer.

In step S25, the control means of the three-dimensional model manufacturing apparatus 200 uses the slice data of the support layer of the three-dimensional model shown in FIG. 10 to perform the support scan 1 on the outbound route from the second head 122 to the support material 202 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the support layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route based on the slice data of the support layer of the three-dimensional model shown in FIG. When the support layer 2 is formed by discharging and flattening the data by the flattening roller 123 and irradiating the UV irradiation unit 124B with ultraviolet rays to cure the data, the process shifts to S26.

In step S26, 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 S21 to step S26 a predetermined number of times, the three-dimensional model of Example 2 shown in FIG. 10 can be obtained.

In the second embodiment, since the corner portion of the expanded support expansion portion is shaped so as to have an R chamfered shape, the support material is torn off at the corner portion of the support expansion portion and is scattered on the side surface of the model portion. It is possible to prevent color mixing and surface roughness due to the adhesion of the support material.

(Example 3)
In Example 3, the three-dimensional modeled object shown in FIG. 12 was modeled using the three-dimensional modeled object manufacturing apparatus 200 shown in FIG. 3 in the same manner as in Comparative Example 1.

Here, FIG. 13 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 third embodiment. Hereinafter, the processing flow of the method for manufacturing the three-dimensional model of Example 3 will be described with reference to FIGS. 3 and 12.

In step S31, when the control means of the three-dimensional model manufacturing apparatus 200 receives the modeling data (slice data) of the three-dimensional model having the target shape shown in FIG. 12, the process shifts to S32.
Here, as shown in FIG. 12A, the three-dimensional model of Example 3 has a shape in which the corners of the support expansion portion are chamfered in a stepped manner with respect to the three-dimensional model of FIG. 4 of Comparative Example 1. It was modeled to be.
As shown in FIGS. 12A to 12C, the support material is expanded in the X and Y directions, and the corners of the expanded support expansion portion are chamfered in a staircase shape. Therefore, there are no sharp corners in the support extension.

In step S32, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the model layer, shifts the process to S33 if it has the model layer, and shifts the process to S34 if it does not have the model layer.

In step S33, the control means of the three-dimensional model manufacturing apparatus 200 is based on the slice data of the model layer of the three-dimensional model shown in FIG. 12, and the model scan 1 is performed on the outbound route from the first head 121 to the model material 201 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers 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 of the three-dimensional model shown in FIG. When the model layer 2 is formed by discharging, flattening by the flattening roller 123, and irradiating ultraviolet rays from the UV irradiation unit 124B to cure the model layer 2, the process shifts to S34.

In step S34, the control means of the three-dimensional model manufacturing apparatus 200 determines the presence or absence of the support layer, shifts the process to S35 if it has the support layer, and shifts the process to S36 if it does not have the support layer.

In step S35, the control means of the three-dimensional model manufacturing apparatus 200 uses the slice data of the support layer of the three-dimensional model shown in FIG. 12 to perform the support scan 1 on the outbound route from the second head 122 to the support material 202 on the stage 111. Is discharged, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the support layer 1. Subsequently, the control means of the three-dimensional model manufacturing apparatus 200 transfers the support material 202 from the second head 122 onto the support layer 1 by the support scan 2 on the return route based on the slice data of the support layer of the three-dimensional model shown in FIG. When the support layer 2 is formed by discharging and flattening the data by the flattening roller 123 and irradiating the UV irradiation unit 124B with ultraviolet rays to cure the data, the process shifts to S36.

In step S36, 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 S31 to step S36 a predetermined number of times, the three-dimensional model of Example 3 shown in FIG. 12 can be obtained.

In the third embodiment, since the corner portion of the expanded support expansion portion is shaped so as to be chamfered in a staircase shape, the support material is torn and scattered at the corner portion of the support expansion portion, so that the model portion is formed. It is possible to prevent color mixing and surface roughness due to the support material adhering to the side surface.

Examples of aspects of the present invention are as follows.
<1> Discharge process for discharging model material and support material, and
A flattening step for flattening the surfaces of the discharged model material and the support material, and
A curing step of curing the flattened model material and the support material, and
Including
The support expansion portion made of the support material is a method for manufacturing a three-dimensional model, characterized in that the width in the sub-scanning direction is formed so as to have a shape that gradually increases or decreases in the main scanning direction.
<2> The method for manufacturing a three-dimensional model according to <1>, wherein the corner portion of the support expansion portion is formed so as to have a C-chamfered shape.
<3> The method for manufacturing a three-dimensional model according to <1>, wherein the corner portion of the support expansion portion is formed so as to have an R chamfered shape.
<4> The method for producing a three-dimensional model according to any one of <1> to <3>, wherein the support material is a water-soluble modeling material.
<5> A program for manufacturing a three-dimensional object, which comprises causing a computer to perform a process of forming a support extension portion so that the width in the sub-scanning direction gradually increases or decreases in the main scanning direction. is there.
<6> The program for manufacturing a three-dimensional model according to <5>, wherein the computer is made to perform a process of forming the corner portion of the support expansion portion into a C-chamfered shape.
<7> The program for manufacturing a three-dimensional model according to <5>, wherein the computer is made to perform a process of forming the corner portion of the support expansion portion into an R-chamfered shape.
<8> The program for manufacturing a three-dimensional model according to any one of <5> to <7>, wherein the support material is a water-soluble modeling material.
<9> The three-dimensional model manufacturing apparatus, which is equipped with the program for manufacturing the three-dimensional model according to any one of <5> to <8>.

The method for manufacturing a three-dimensional model according to any one of <1> to <4>, the program for manufacturing a three-dimensional model according to any one of <5> to <8>, and the above-mentioned <9>. According to the three-dimensional model manufacturing apparatus, it is possible to solve various conventional problems and achieve the object of the present invention.

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

JP-A-2019-147343

Claims (8)

Discharge process for discharging model material and support material,
A flattening step for flattening the surfaces of the discharged model material and the support material, and
A curing step of curing the flattened model material and the support material, and
Including
A method for manufacturing a three-dimensional object, wherein the support expansion portion made of the support material is formed so that the width in the sub-scanning direction gradually increases or decreases in the main scanning direction. The method for manufacturing a three-dimensional model according to claim 1, wherein the corners of the support expansion portion are formed so as to have a C-chamfered shape. The method for manufacturing a three-dimensional model according to claim 1, wherein the corners of the support expansion portion are formed so as to have an R chamfered shape. The method for producing a three-dimensional model according to any one of claims 1 to 3, wherein the support material is a water-soluble modeling material. A program for manufacturing a three-dimensional object, which comprises causing a computer to perform a process in which the width of the support extension portion in the sub-scanning direction is formed so as to have a shape that gradually increases or decreases toward the main scanning direction. The program for manufacturing a three-dimensional model according to claim 5, wherein a computer is made to perform a process of forming the corner portion of the support expansion portion into a C-chamfered shape. The program for manufacturing a three-dimensional model according to claim 5, wherein a computer is made to perform a process of forming the corner portion of the support expansion portion into an R-chamfered shape. A three-dimensional model manufacturing apparatus comprising the program for manufacturing a three-dimensional model according to any one of claims 5 to 7.

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