JP2021146643A - Three-dimensional shaped product producing device, three-dimensional shaped product producing method, and program for producing three-dimensional shaped product - Google Patents

Abstract

To provide a three-dimensional shaped product producing device capable of reducing collision of a roller to a three-dimensional shaped product by reducing formation of convex streaks, in a shaping method using a scheme of providing a shaping material into layers and laminating the layers to form the three-dimensional shaped product, or preferably a material jetting scheme.SOLUTION: A three-dimensional shaped product producing device includes: ejecting means for ejecting a shaping material; curing means for curing the shaping material ejected by the ejecting means; and control means for performing control to cause the ejecting means to further eject a repair shaping material to shaping layers formed so as to have a prescribed thickness by the ejecting means and the curing means, and to cause flattening means to flatten the product to the prescribed thickness. The amount of the repair shaping material to be ejected to one region, for forming at least the repairing shaping layer, is less than the amount of the repair shaping material to be ejected to other regions.SELECTED DRAWING: Figure 5

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) is known. Among these, the material jetting (MJ) method is known as a modeling technique by the inkjet method. 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, for example, by forming a hollow portion in which the modeling material is not discharged or the discharge amount is reduced in the formation of slices, the roller is molded below the original position, so that the roller is formed. A three-dimensional modeling device capable of preventing contact with a modeling surface has been proposed (see, for example, Patent Document 1).

The present invention provides a three-dimensional model by reducing the formation of convex streaks in a method of applying a modeling material in layers and laminating the materials to form a three-dimensional model, preferably a material jetting method. It is an object of the present invention to provide a three-dimensional model manufacturing apparatus capable of reducing collision of rollers, which is a flattening means of the above.
Here, the "convex streak" is a region that is not flattened by the flattening roller in a configuration in which the length in the longitudinal direction of the flattening roller as the flattening means is shorter than the length in the nozzle row direction of the head as the discharge means. It means the part where the repair molding layer or the model layer is higher than the target flattening height.

The three-dimensional model manufacturing apparatus of the present invention as a means for achieving the above object includes a discharge means for discharging a modeling material, a curing means for curing the modeling material discharged by the discharge means, and the discharge. A control means for controlling the ejection means to further eject a modeling material for repair to the modeling layer formed to a predetermined thickness by the means and the curing means, and the flattening means to flatten the forming layer to the predetermined thickness. A three-dimensional model manufacturing apparatus having a ..

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 formation of convex streaks is reduced to reduce the formation of the three-dimensional model. It is possible to provide a three-dimensional model manufacturing apparatus capable of reducing the collision of rollers, which is a means for flattening the object.

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 view showing the positional relationship between the head and the roller as viewed from directly above. FIG. 3A is a model first layer, FIG. 3B is a model second layer, and FIG. 3C is a repair molding layer. show. FIG. 4 is a diagram showing an example of means for controlling the discharge amount. FIG. 5 is a flowchart showing an example of the flow of processing for generating slice data in which the discharge amount is controlled. FIG. 6 is a schematic view showing an example of the three-dimensional model manufacturing apparatus of the present invention. FIG. 7A is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the outbound route of the first layer of the model. FIG. 7B is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the return path of the first layer of the model. FIG. 7C is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the outbound route of the second layer of the model. FIG. 7D is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the return path of the second layer of the model. FIG. 7E is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the return path of the repair modeling layer. FIG. 7F is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the outbound route of the third layer of the model layer. FIG. 7G is a view showing a state in which the process of the modeling of Comparative Example 1 is viewed from the front, and is a diagram showing the modeling of the return path of the third layer of the model layer. FIG. 8A is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the first layer of the model. FIG. 8B is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the first layer of the model. FIG. 8C is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the second layer of the model. FIG. 8D is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the second layer of the model. FIG. 8E is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the repair modeling layer. FIG. 8F is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the third layer of the model layer. FIG. 8G is a view showing a state in which the process of the modeling of the first embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the third layer of the model layer. FIG. 9A is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the first layer of the model. FIG. 9B is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the first layer of the model. FIG. 9C is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the second layer of the model. FIG. 9D is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the second layer of the model. FIG. 9E is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the repair modeling layer. FIG. 9F is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the outbound route of the third layer of the model layer. FIG. 9G is a view showing a state in which the process of the modeling of the second embodiment is viewed from the front, and is a diagram showing the modeling of the return path of the third layer of the model layer.

(Manufacturing method of three-dimensional model and device for manufacturing three-dimensional model)
The three-dimensional model manufacturing apparatus of the present invention has a discharge means for discharging a modeling material, a curing means for curing the modeling material discharged by the discharging means, and a predetermined thickness by the discharging means and the curing means. It is a three-dimensional model manufacturing apparatus having a control means in which the discharge means further discharges a repair modeling material to the modeled modeling layer and the flattening means controls the flattening to the predetermined thickness. Therefore, at least the discharge amount of the repair modeling material in a part area for forming the repair modeling layer is set to be less than the discharge amount of the repair modeling material in the other area, and other means are provided as necessary. ..

The method for producing a three-dimensional model of the present invention includes a discharge step of discharging a modeling material, a curing step of curing the modeling material discharged in the discharge step, and the discharge step after at least one curing step. And at least a repair molding layer including a repair step of discharging a repair molding material to a molding layer formed to a predetermined thickness in the curing step and flattening the molding layer to the predetermined thickness by a flattening means. The discharge amount of the repair molding material in a part of the region is set to be less than the discharge amount of the repair molding material in the other region, and other steps are included as necessary.

The method for producing a three-dimensional model of the present invention can be suitably carried out by the three-dimensional model manufacturing apparatus of the present invention, the discharge step can be performed by the discharge means, and the curing step can be performed by the curing means. The repair step can be performed by controlling the discharge means and the flattening means by the control means, and the other steps can be performed by using the other means and / or the control means to control the discharge means, the curing means and the flattening means. It can be done by controlling.

In the prior art, the discharge amount of the repair molding material or the modeling material is uniform on the discharge region of the modeling material, regardless of whether or not the ejection region is flattened by the roller as the flattening means. However, if the longitudinal length of the rollers is shorter than the nozzle row length, the repair molding material or shaping material in the unflattened area will be greater than the height of the repair shaping layer or shaping layer in the flattened area. There is a problem that the flattening roller, which is a flattening means, collides with the modeled object in the subsequent formation of the modeling layer.

When a flattening means is used for flattening the molding material discharged from the nozzle of the head as the discharging means, the length in the longitudinal direction of the flattening roller as the flattening means is usually the nozzle row direction of the head as the discharging means. It is practiced to use a flattening means shorter than the length of.
Ideally, the discharge means (head) and the flattening means (roller) should be exactly the same length, but this is not the case due to manufacturing errors. Both the problem and the problem that arises when shortening need to be addressed.
Therefore, we usually narrow down the problems to be dealt with by intentionally moving them to one side.
If the length of the roller is longer than the length of the head, all the ejected objects can be flattened, but if the roller is ejected with a "line feed", it will interfere with the already formed "row". Rollers are prone to breakage. On the other hand, when the length of the roller is shorter than the length of the head, it is not possible to flatten all the discharged molding materials, and the unflattened portion remains as a convex streak. The height of this convex streak is usually lower than the thickness of the next layer (the sum of the thicknesses formed on both the outward and return paths when ejected on the outward and return paths and flattened on the return path). The amount to be scraped is not usually larger than the amount to be left), so this is usually not a problem when stacking is repeated.
However, when the length in the longitudinal direction of the flattening roller as the flattening means is shorter than the length in the nozzle row direction of the head as the discharge means, when the repair molding layer is formed, the repair molding layer discharges. Since all the repair molding materials are collected by the rollers, the convex streaks after forming the repair molding layer are higher than those of the conventional convex streaks by the amount of the repair molding layer, and as a result, the convex streaks and rollers of the modeled product are formed. The problem of collision arises.

Therefore, in the present invention, the molding material is discharged to a predetermined thickness by the discharging means for discharging the modeling material, the curing means for curing the modeling material discharged by the discharging means, and the discharging means and the curing means. A three-dimensional model manufacturing apparatus comprising: a control means for further discharging a repair modeling material to a modeling layer and controlling the flattening means to flatten the material to a predetermined thickness. The discharge amount of the repair modeling material in a part area for forming the repair modeling layer shall be less than the discharge amount of the repair modeling material in the other area. Specifically, by reducing or eliminating the discharge amount of the repair molding material at the convex streak forming portion (including the repair molding layer and the molding layer below it), the height of the repair molding layer that cannot be tolerated at the time of formation. It is possible to prevent the convex streaks from being formed, and it is possible to avoid the collision of the flattening roller with the convex streaks of the three-dimensional model.

In the present invention, the "modeling layer" means a layer formed by applying a modeling material in a layered manner, flattening and curing the material. For example, in a mode in which the discharging means discharges the modeling material in a layered manner during a reciprocating scan, when the modeling material is discharged, flattened, and cured once in the outward path, the layer formed in the outward path is the modeling layer. Yes, when the modeling material is discharged on the outward route, but not flattened, and is arbitrarily cured, and when the modeling material is further discharged, flattened, and cured on the return route, the layer formed by such reciprocation is the modeling layer. Become. "Modeling material" means a material discharged from a discharge means in the manufacture of a modeled object, and typically when modeling a model material for forming the three-dimensional modeled object itself, an overhang portion, a detail portion, or the like. Examples of the support material used for the above. 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”.
"Shaping to a predetermined thickness" means that flattening and curing are performed so as to have a predetermined thickness.
The repair modeling layer is formed by discharging the repair modeling material to the "modeling layer formed to a predetermined thickness", flattening the material to the predetermined thickness, and curing the material. As the "repair modeling material" discharged here, the same modeling material as the modeling material forming the modeling layer to which the repair modeling material is discharged is used.
The repair molding layer means a molding layer formed by discharging, flattening, and curing the repair molding material in a state where the flattening means is not raised (a state in which the height of the flattening means is not changed). It mainly plays a role of filling the difference at the end of the modeling layer. As a result, the edge quality of the three-dimensional model can be improved. Therefore, the repair molding layer is preferably formed with respect to the model layer.

The repair molding material may be discharged on the outward path, may be discharged on the return path, or may be discharged on both the outward path and the return path. When the repair molding material is discharged on the outward route, the repair molding layer is not adversely affected on the molding quality by the flattening means colliding with the cured repair molding layer on the subsequent return route. It is preferable not to cure. As described above, since the repair modeling layer is preferably formed on the model layer, a repair model material is preferably used as the repair modeling material.

In the present invention, the discharge means reciprocates horizontally with respect to the modeled object (modeling table) in a predetermined direction (hereinafter, referred to as "main scanning direction" or "X direction") (hereinafter, discharge means and modeling). The movement relative to the table is called "scanning"), and the modeling material is discharged on the outward and / or return routes. In order to improve productivity, the discharge means may have a plurality of discharge holes, and typically, the plurality of discharge holes are orthogonal to the main scanning direction (hereinafter, "secondary scanning direction" or "Y direction"). ”) Are lined up at regular intervals to form a row. In the present invention, "printing" means discharging a modeling material by a discharge means and curing it by a curing means at the time of reciprocating scanning in the main scanning direction. The range that can be printed by scanning in the main scanning direction once is called a "line", and scanning the discharging means in the sub-scanning direction and moving the discharging means to a different line is called a "line feed". As a general rule, the fixed interval between the discharge holes does not change even if a line break occurs, and when printing is performed in the entire modeling range by repeating the line break, the fixed interval is set in the sub-scanning direction with reference to the discharge hole position at the start of modeling. , The position of the discharge hole when forming a certain layer is determined, and this determined position is set as the specified position. In the present invention, "normal printing" means printing performed at a predetermined discharge hole position such as the specified position.

In one aspect of the present invention, the discharge amount of the repair molding material only in the non-flattened region is controlled to be less than or zero than the thickness of the repair molding layer in the flattened region. That is, by preventing the convex streaks from growing, it can be realized by controlling so as to reduce or eliminate the amount of the repair molding material accumulated on the convex streaks when the repair molding layer is formed.
By controlling the discharge amount of the repair molding material only in the non-flattened region to be less than or zero than the thickness of the repair molding layer in the flattened region, the modeled object of the flattening roller. The collision with the convex streaks can be eliminated, and the discharge amount of the repair molding material is not lowered in the flattened region, so that the effect of reducing the R of the edge angle can be fully utilized.

In one aspect of the present invention, the discharge amount of the modeling material in the non-flattened region is controlled to be less than the thickness of the modeling layer in the flattened region. By controlling the discharge amount of the modeling material in the non-flattened region to be less than the thickness of the modeling layer in the flattened region, it is possible to eliminate the collision of the flattening roller with the convex streaks of the modeled object. At the same time, it is possible to prevent a pattern from appearing on the outermost surface of the modeled object due to the presence or absence of the repaired modeling layer.

<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 for modeling the modeling layer is not particularly limited, and can be appropriately selected based on the performance required for constructing the main body for modeling the three-dimensional model (model part). For example, a model material, Examples include repair model materials. 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 modeling material for modeling a portion constituting the model portion.
The repair model material is a modeling material that is discharged for the purpose of repairing a modeling layer formed to a predetermined thickness. In a preferred embodiment, the repair model material is the same material (composition, concentration, etc.) as the model material.
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”). 1 to 40 molar adducts of EO stearate, etc.], polyhydric alcohol-type nonionic surfactants (eg, sorbitan palmitate monoester, sorbitan stearic acid monoester, sorbitan stearic acid triester, etc.), fluorine-containing surfactants (eg, sorbitan stearic acid triester, etc.) , PerfluoroalkylEO 1 to 50 molar additions, perfluoroalkylcarboxylic acid salts, perfluoroalkyl betaines, etc.), modified silicone oils [eg, polyether-modified silicone oils, (meth) acrylate-modified silicone oils, etc.] and the like. .. 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 metahydrosulfate and sodium hydrogen sulfite, 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 modeling 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 molding 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.

<Repair process and 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 repair step is a step of further discharging a molding material for repair to a molding layer formed to a predetermined thickness in the discharge step and flattening the molding material to the predetermined thickness by a flattening means, and the control means It is carried out by controlling the operation of each means.
After forming the modeling layer by the action of the control means, the repair modeling material is discharged again at the same height without changing the Z direction position (height) of the flattening means, and flattening and hardening are performed. , The difference between the ideal flattening surface and the roundness of the end of the modeling layer can be reliably filled, and the edge quality of the three-dimensional model can be improved.

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. 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 molding 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.
By flattening the molding layer made of the molding material discharged by the flattening means, the accuracy and flatness of the average thickness of the molding 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.

The three-dimensional model manufacturing device (hereinafter, may be referred to as “three-dimensional modeling device”) 10 is a material injection modeling device, and is a modeling stage in which a modeling layer 30 which is a layered model is laminated to form a three-dimensional model. The stage 14 is provided with a modeling unit 20 for modeling while sequentially laminating the modeling layer 30 on the stage 14.

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. In addition to the modeling material as a model material for modeling the three-dimensional model, the second head 12 for discharging the support material that supports the modeling of the three-dimensional model 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 optical systems 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, the 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. do.
After forming the modeling layer 30, the repair modeling material is discharged again at the same height without changing the Z-direction position (height) of the flattening roller 16, and flattening and hardening are performed to form the repair modeling layer. Form. As a result, the difference between the ideal flattening surface and the roundness of the end of the modeling layer can be reliably filled, and the edge quality of the three-dimensional model can be improved.

The modeling layer 30 and the repair modeling layer are repeatedly modeled and laminated in sequence, and the target three-dimensional model composed of the model material 301 is modeled while the model material 301 is supported by 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 modeling 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 ambient temperature in the apparatus at the time of modeling may be controlled.

(Program for manufacturing 3D objects)
In the three-dimensional model manufacturing program of the present invention, a computer is made to perform a process of further discharging a repair modeling material to a modeling layer made of a modeling material formed to a predetermined thickness.

The three-dimensional model manufacturing program can cause a computer to perform other processes in addition to the process of discharging the repair modeling material to the modeling layer made of the modeling material formed to a predetermined thickness.
Other treatments include, for example, a treatment of flattening the layer of the discharged molding material, a treatment of irradiating the discharged molding material with active energy rays to cure the discharged molding material, and the like.

Since the three-dimensional model manufacturing program of the present invention is realized as the three-dimensional model manufacturing apparatus of the present invention by using a computer or the like as a hardware resource, a preferred embodiment in the three-dimensional model manufacturing program 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 model of the present invention can be created by using various known programming 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 object 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 a computer system through an 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. Examples include memory.
Further, the computer-readable recording medium of the present invention may be a plurality of recording media in which the program for manufacturing a three-dimensional model of the present invention is divided and recorded for each arbitrary process.

The processing by the program for producing a three-dimensional object of the present invention can be executed by using a computer having a control means constituting the three-dimensional object manufacturing apparatus of the present invention.
The computer is not particularly limited as long as it is a device provided 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 comprises 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.
After forming the modeling layer 30, the control means 500 controls to discharge and flatten the repair modeling material again at the same height without changing the Z-direction position (height) of the flattening roller 16. As a result, the difference between the ideal flattening surface and the roundness of the end of the modeling layer can be reliably filled, and the edge quality of the three-dimensional model can be improved.

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 modeling device is configured by the modeling data creating device 600 and the three-dimensional modeling object manufacturing device 10.

Here, FIG. 3 is a diagram showing the positional relationship between the head as the discharging means and the roller as the flattening means in the present invention as viewed from directly above, and FIG. 3 (A) is a model 1 layer. Eyes, FIG. 3B shows the second model layer, and FIG. 3C shows the repair model layer.

<Movement in the main scan and sub scan directions>
When modeling a large model in the sub-scanning direction (= Y direction), the model layer and the repair model layer are modeled by a combination of reciprocating operation in the main scanning direction (= X direction) and movement in the sub-scanning direction. Is done.
As shown in FIGS. 3A and 3B, one model layer is composed of four main scanning directions, and reciprocating operations in various scanning directions are "first line feed", "second line feed", and "second line feed". "3 line breaks" and "4th line breaks".

<Head feed>
As shown in FIG. 3B, the position of the head in the Y direction when forming the second layer of the model is shifted from the position in the Y direction of the head when forming the first layer of the model. .. The purpose of this is to prevent the non-ejection nozzles from printing the same position on each model layer when a non-ejection nozzle occurs. Further, the operation of shifting the head position when forming the succeeding model layer with respect to the preceding model layer in the sub-scanning direction (= Y direction) is called "head feed" ((A) in FIG. 3). ) And (B) in FIG.
However, as shown in FIG. 3 (C), the head feed is not performed in the formation of the repair model layer (see (B) in FIG. 3 and (C) in FIG. 3). The reason for this is that the repair model material is an operation in which the repair model material is discharged and flattened by the flattening roller without raising the roller in the height direction (Z direction) with respect to the preceding model material. Therefore, when the flattening roller is tilted, the flattening roller collides with the preceding model layer.

<Convex streak formation>
As shown in FIG. 3A, in the first layer of the model, the "region 1a" is ejected when the "second line feed" is formed, but the "region 1a" is cured without being flattened by the flattening roller. Therefore, it is shaped higher than the region flattened by the flattening roller. That is, convex streaks are formed on the three-dimensional model.
As shown in FIG. 3B, in the second layer of the model, the "region 1b" is discharged when the "second line feed" is formed, but the "region 1b" is cured without being flattened by the flattening roller. Therefore, it is formed higher than the region flattened by the flattening roller. That is, convex streaks are formed on the three-dimensional model.
As shown in FIG. 3C, in the repair model layer, the "region 1c" is discharged when the "second line feed" is formed, but the "region 1c" is cured without being flattened by the flattening roller. Therefore, it is formed higher than the region flattened by the flattening roller. That is, convex streaks are formed on the three-dimensional model.

<Discharge amount control means>
Next, a control means for reducing or reducing the discharge amount of the repair model material or the model material in the non-roller flattening region will be described.
As shown in FIG. 4, in a configuration in which the flattening roller length is shorter than the nozzle row length of the head, there is a nozzle 5c at the end of the head where the discharged repair model material or the model material is not flattened by the rollers. ..
The nozzle 5c can be controlled so as not to eject the repair model material or the model material in the "slice data" generation process, and the repair model layer or model can be formed by modeling with the slice data generated by the process. In a layer having layers, it can be modeled as an image as shown in 5a in FIG.
Further, when reducing the discharge amount of the repair model material or the model material, a method of reducing the discharge amount per unit area by thinning out the dots to which the repair model material or the model material is discharged in the non-roller flattening region is used. (5b in FIG. 4). Of course, the discharge amount of the nozzle 5c itself may be reduced.

The repair model layer is formed for each of a plurality of model layers, for example, every two layers or every three layers of the model layer. In yet another aspect of the present invention, the repair model layer is preferably formed each time one slice layer is formed.
In the present invention, the "slice layer" means a laminated unit composed of a combination of a plurality of model layers and optionally one or more support layers. The "laminated unit" is formed by a predetermined ejection, flattening and curing pattern, and a three-dimensional model is formed by repeating such a laminated unit, that is, by repeating such a forming pattern.
The data that forms the "slice layer" is the "slice data".

Here, FIG. 5 is a flowchart showing an example of the flow of the process of generating the repair model material or the “slice data” in which the discharge amount of the model material is controlled.

In step S1, when the control means of the three-dimensional model manufacturing apparatus acquires the modeling data, the process shifts to S2. Here, the modeling data is input in, for example, an STL file.

In step S2, when the control means of the three-dimensional model manufacturing apparatus calculates the area information of the support material required for modeling the three-dimensional model, the process shifts to S3.

In step S3, when the control means of the three-dimensional model manufacturing apparatus performs necessary correction processing such as a base layer, a frame portion, and an interface thinning process, the process shifts to S4.

In step S4, when the control means of the three-dimensional model manufacturing apparatus performs the discharge amount control process in the non-roller flattening region in order to reduce the occurrence of convex streaks of the model, the process shifts to S5. The discharge amount control process is as described in the discharge amount control means described above.

In step S5, when the control means of the three-dimensional model manufacturing apparatus outputs the final discharge data, this process ends.

By performing the process shown in FIG. 5, the discharge amount of the repair model material or the model material can be reduced or reduced to zero in the non-roller flattening region.

Hereinafter, examples of the present invention will be described, but the present invention is not limited to these examples.
Hereinafter, examples of the present invention will be described, but the present invention is not limited to these examples. In the examples and comparative examples shown below, the movement of the modeling unit in the Y direction (secondary scanning direction, parallel to the nozzle row) is omitted for simplification. If the modeling area is larger than the movement width of the first and second heads of the modeling unit, the modeling unit is appropriately moved in the Y direction. In the following examples and comparative examples, "modeling material" is "model material", "modeling layer" is "model layer", "repairing modeling material" is "repair model material", and "repair modeling". The "layer" will be described as a "repair model layer".

(Comparative Example 1)
The three-dimensional model manufacturing apparatus 200 shown in FIG. 6 includes a modeling stage 111 on which the three-dimensional modeling object 110 is placed, and a modeling unit 120 for modeling while sequentially stacking the modeling objects 110 on the modeling stage 111.

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.

In Comparative Example 1, the three-dimensional model manufacturing apparatus 200 shown in FIG. 6 is used to manufacture the three-dimensional model as shown below.

First, as shown in FIG. 7A, in the outbound route of the first layer of the model, the model material is discharged from the first head 121 onto the stage 111, irradiated with ultraviolet rays from the UV irradiation unit 124A, and cured to form the model layer 1. Form.

Next, as shown in FIG. 7B, in the return path of the first layer of the model, the model material is discharged from the first head 121 onto the model layer 1, flattened by the flattening roller 123, and the ultraviolet rays are emitted from the UV irradiation unit 124B. Is irradiated and cured to form the model layer 2. At this time, since the length of the flattening roller 123 is shorter than the length of the first head 121, a convex streak 2a is formed on the model layer 2 after the second line feed.

Next, as shown in FIG. 7C, in the outbound route of the second layer of the model, the modeling unit 120 rises by a predetermined amount in the Z direction, the model material is discharged from the first head 121 onto the model layer 2, and the UV irradiation unit 124A Is irradiated with ultraviolet rays and cured to form the model layer 3. At this time, since flattening is not performed by the flattening roller on the outward path, the convex streaks 2b are maintained.

Next, as shown in FIG. 7D, in the return path of the second layer of the model, the model material is discharged from the first head 121 onto the model layer 3, flattened by the flattening roller 123, and ultraviolet rays are emitted from the UV irradiation unit 124B. Is irradiated and cured to form the model layer 4. At this time, a convex streak 2ca is formed after the second line feed. Since the height of the convex streaks 2ca is higher than that of the model layer 4, the convex streaks 2b up to the model layer 3 are filled and a new convex streaks 2ca are formed.

Next, in the repair model layer outbound route, the repair modeling material is not discharged (not shown).

Next, as shown in FIG. 7E, in the repair model layer return path, the repair model material is discharged from the first head 121 onto the model layer 4, flattened by the flattening roller 123, and UV irradiation unit 124B. Is irradiated with ultraviolet rays and cured to form a repair model layer 6. Here, the convex streak 2da is formed again at the same position as the convex streak 2ca. The height of the repair model layer 6 minutes is piled up on the convex streaks as it is, and the height is maintained as it is and cured.
In the repair model layer 6, since all the discharged repair model materials are collected by the flattening roller, the convex streaks after forming the repair model layer 6 are higher than the conventional convex streaks by the repair model layer. Become. As a result, it interferes with the rollers when the next layer is formed.

Next, the head Md is raised and the head is fed.

Next, as shown in FIG. 7F, in the outbound route of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 6 for repair, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model. The model layer 7 is formed. Here, the convex streaks 2ea are formed again at the same positions as the convex streaks 2da. This is because the height is maintained as it is without being flattened by the flattening roller 123 on the outward route, and as a result, a convex streak thicker than the thickness of the model layer 8 is formed on the return route of the third layer of the model.

Next, as shown in FIG. 7G, in the return path of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 8, flattened by the flattening roller 123, and irradiated with ultraviolet rays from the UV irradiation unit 124B. And cure to form the model layer 8. Here, at the time of flattening by the flattening roller 123, the flattening roller 123 collides with the convex streaks 2ea. That is, the convex streaks 2ea collide with the flattening roller 123 at the time of flattening on the return path of the third layer of the model. This is because when the repair model layer 6 is formed, the convex streaks grow and become higher than the thickness of the next return path layer (model layer 8).

<Evaluation of Comparative Example 1>
In Comparative Example 1, when the model 3rd layer return path is formed, the height of the convex streaks formed before the model 3rd layer return path is higher than the height that the flattening roller passes through when the model 3rd layer return path is formed. Therefore, there is a problem that the flattening roller 123 collides with the convex streaks of the modeled object in the return path of the third layer of the model.

(Example 1)
In order to eliminate the collision of the flattening roller with the convex streaks of the modeled object, which is the problem of Comparative Example 1, the height of the convex streaks formed before the outward path of the third layer of the model is increased when the return path of the third layer of the model is formed. It was found that collision can be avoided if the flattening roller is lower than the height of the convex streaks to which it is added. Therefore, in the first embodiment, the discharge amount of the repair model material in the region not flattened by the flattening roller is reduced or is not discharged (zero).

<Sequence>
8A to 8C are the same as those of FIGS. 7A to 7C, and thus the description thereof will be omitted.

Next, as shown in FIG. 8D, in the return path of the second layer of the model, the model material is discharged from the first head 121 onto the model layer 3, flattened by the flattening roller 123, and irradiated with ultraviolet rays from the UV irradiation unit 124B. Then, it is cured to form the model layer 4. Here, the convex streaks 3ca are formed.

Next, in the outbound route of the repair model layer, the repair model material is not discharged (not shown).

Next, as shown in FIG. 8E, in the repair model layer return path, the repair model material is discharged from the first head 121 onto the model layer 4, flattened by the flattening roller 123, and ultraviolet rays are emitted from the UV irradiation unit 124B. Is irradiated and cured to form a repair model layer 6. Here, the repair model material is not discharged in the region of the convex streaks 3ca.

Next, the head Md is raised and the head is fed.

Next, as shown in FIG. 8F, in the outbound route of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 6 for repair, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model. The model layer 7 is formed.

Next, as shown in FIG. 8G, in the return path of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 7, flattened by the flattening roller 123, and irradiated with ultraviolet rays from the UV irradiation unit 124B. And cure to form the model layer 8. Here, since the height of the convex streaks on the convex streaks 3ca is equal to or less than the height through which the flattening roller 123 passes, the flattening roller 123 does not collide with the convex streaks of the modeled object.

<Evaluation of Example 1>
According to the first embodiment, it is possible to eliminate the collision of the flattening roller with the convex streaks of the modeled object, which is a problem of the comparative example 1.
However, in the first embodiment, when the discharge amount of the repair model material in the region not flattened by the flattening roller 123 is set to zero, the repair model material is discharged and the repair model material is not discharged. Exists on the surface of the modeled object. Therefore, there is a problem that the surface of the final modeled object is visually recognized as having a pattern depending on the viewing angle.

(Example 2)
Since the pattern on the surface of the modeled object is not generated, which is the problem of Example 1, the discharge amount of the repair model material in the region not flattened by the rollers is limited to being reduced without being reduced to zero, and further, in the second layer return path of the model. , A method of reducing the discharge amount in the region corresponding to the convex streak 3ca is adopted.

<Sequence>
Since FIGS. 9A to 9C are the same as those of FIGS. 7A to 7C, the description thereof will be omitted.

Next, as shown in FIG. 9D, in the second layer return path of the model, the model material is discharged from the first head 121 onto the model layer 3, flattened by the flattening roller 123, and irradiated with ultraviolet rays from the UV irradiation unit 124B. Then, it is cured to form the model layer 4. Here, in the region 4ca that is not flattened by the flattening roller 123, the discharge amount of the model material is reduced.

Next, in the outbound route of the repair model layer, the repair model material is not discharged (not shown).

Next, as shown in FIG. 9E, in the repair model layer return path, the repair model material is discharged from the first head 121 onto the model layer 4, flattened by the flattening roller 123, and ultraviolet rays are emitted from the UV irradiation unit 124A. Is irradiated and cured to form a repair model layer 6. Here, in the region 4da that is not flattened by the flattening roller 123, the discharge amount of the repair model material is reduced.

Next, the head Md is raised and the head is fed.

Next, as shown in FIG. 9F, in the outbound route of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 6 for repair, and ultraviolet rays are irradiated from the UV irradiation unit 124A to cure the model. The model layer 7 is formed.

Next, as shown in FIG. 9G, in the return path of the third layer of the model, the model material is discharged from the first head 121 onto the model layer 7, flattened by the flattening roller 123, and irradiated with ultraviolet rays from the UV irradiation unit 124B. And cure to form the model layer 8. Here, since the height of the convex streaks on the convex streaks 4da is equal to or less than the height through which the flattening rollers pass, the flattening rollers 123 do not collide with the modeled object.

<Evaluation of Example 2>
According to the second embodiment, it is possible to eliminate the collision of the flattening roller with the convex streaks of the modeled object, which is a problem of the comparative example 1.
Further, it is possible to solve the problem of the first embodiment that the surface of the final modeled object is visually recognized as having a pattern depending on the viewing angle.

Examples of aspects of the present invention are as follows.
<1> Discharging means for discharging the modeling material and
A curing means for curing the modeling material discharged by the discharging means, and
Control that the discharge means further discharges the repair molding material to the modeling layer formed to the predetermined thickness by the discharging means and the curing means, and the flattening means controls to flatten the modeling material to the predetermined thickness. Means and
It is a three-dimensional model manufacturing device with
It is a three-dimensional model manufacturing apparatus characterized in that the discharge amount of the repair modeling material in a part area for forming at least the repair modeling layer is less than the discharge amount of the repair modeling material in the other area. ..
<2> In the above <1>, the discharge amount of the repair molding material only in the non-flattened region is controlled to be less than or zero than the thickness of the repair molding layer in the flattened region. The three-dimensional model manufacturing apparatus described.
<3> The three-dimensional model manufacturing apparatus according to <1> or <2>, wherein the discharge amount of the modeling material in the non-flattened region is controlled to be less than the thickness of the modeling layer in the flattened region. be.
<4> The feature is that the computer is made to perform a process of making the discharge amount of the repair molding material in a part area less than the discharge amount of the repair molding material in another area at least for forming the repair molding layer. This is a program for manufacturing three-dimensional objects.
<5> A three-dimensional model manufacturing apparatus equipped with the program for manufacturing a three-dimensional model according to the above <4>.
<6> Discharge process for discharging modeling materials and
A curing step of curing the modeling material discharged in the discharging step, and a curing step of curing the modeling material.
After at least one curing step, the repair molding material is discharged to the molding layer formed to a predetermined thickness in the discharging step and the curing step, and flattened to the predetermined thickness by the flattening means. Including the repair process and
A method for manufacturing a three-dimensional model, characterized in that the discharge amount of the repair modeling material in a part area for forming at least the repair modeling layer is less than the discharge amount of the repair modeling material in the other area. be.

The three-dimensional model manufacturing apparatus according to any one of <1> to <3> and <5>, the three-dimensional model manufacturing program according to <4>, and the three-dimensional model according to <6>. According to the manufacturing method, various problems in the prior art can be solved and the object of the present invention can be achieved.

10 Three-dimensional model manufacturing equipment 11 1st head 12 2nd head 13 UV irradiation unit 14 Stage 16 Flattening roller 20 Modeling unit 30 Modeling layer

Japanese Unexamined Patent Publication No. 2013-067118

Claims (6)

Discharge means for discharging modeling materials and
A curing means for curing the modeling material discharged by the discharging means, and
Control that the discharge means further discharges the repair molding material to the modeling layer formed to the predetermined thickness by the discharging means and the curing means, and the flattening means controls to flatten the modeling material to the predetermined thickness. Means and
It is a three-dimensional model manufacturing device with
A three-dimensional model manufacturing apparatus characterized in that the discharge amount of the repair modeling material in a part area for forming at least the repair modeling layer is less than the discharge amount of the repair modeling material in the other area. The three-dimensional modeling according to claim 1, wherein the discharge amount of the repair molding material only in the non-flattened region is controlled to be less than or zero than the thickness of the repair molding layer in the flattened region. Product manufacturing equipment. The three-dimensional model manufacturing apparatus according to claim 1 or 2, wherein the discharge amount of the modeling material in the non-flattened region is controlled to be less than the thickness of the modeling layer in the flattened region. A solid characterized by having a computer perform a process of making the discharge amount of the repair molding material in a part region less than the discharge amount of the repair molding material in another region for forming at least the repair molding layer. A program for manufacturing shaped objects. A three-dimensional model manufacturing apparatus comprising the program for manufacturing a three-dimensional model according to claim 4. The discharge process that discharges the modeling material and
A curing step of curing the modeling material discharged in the discharging step, and a curing step of curing the modeling material.
After at least one curing step, the repair molding material is discharged to the molding layer formed to a predetermined thickness in the discharging step and the curing step, and flattened to the predetermined thickness by the flattening means. Including the repair process and
A method for manufacturing a three-dimensional model, characterized in that the discharge amount of the repair modeling material in a part region for forming at least the repair modeling layer is less than the discharge amount of the repair modeling material in the other region.

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