JP4420685B2 - 3D object forming apparatus and 3D object forming method - Google Patents

Description

  The present invention relates to a three-dimensional object forming apparatus and a three-dimensional object forming method for forming a laminated body having a predetermined shape by laminating ink using cured ink.

  Conventionally, flat printing is performed using a printing apparatus such as a general-purpose inkjet printer. In addition, there is an apparatus for assembling a three-dimensional three-dimensional object (see, for example, Patent Document 1). The apparatus described in Patent Document 1 assembles one type of three-dimensional object using one nozzle.

JP-A-5-345359

  However, in the above prior art, a three-dimensional object cannot be formed with high resolution. A conventional printing apparatus cannot form a three-dimensional object because ink penetrates the paper surface. On the other hand, since the apparatus described in Patent Document 1 is a structure in which a material is extruded from a nozzle and a three-dimensional object is assembled, the resolution is coarse (for example, about 0.2 mm), and a three-dimensional object having a minute shape is used. A high resolution could not be formed. In addition, there is a method of forming a three-dimensional object using a mold, but in this case, there is a limit to miniaturization and high resolution.

  An object of the present invention is to provide a three-dimensional object forming apparatus and a three-dimensional object forming method capable of forming a three-dimensional object with high resolution in order to solve the above-described problems caused by the prior art. .

To solve the above problems and achieve an object, Ru engages the present invention 3-dimensional object forming apparatus includes an ink head for ejecting UV curable ink which is cured by irradiation of ultraviolet rays, ultraviolet rays to cure the UV curable ink the ink performs an irradiation head for irradiating a smooth surface member having a reference surface for stacking U V curing ink discharged from the ink head, the control to move relative to the ink head and the irradiating head Control means for controlling the discharge of UV curable ink from the head and the irradiation of ultraviolet rays by the irradiation head, and shape data of a three-dimensional object laminated on the reference surface have a predetermined thickness on the reference surface. Storage means for storing the data divided into a plurality of layers. The predetermined thickness constituting each of the plurality of layers is set to a thickness of one layer formed when UV curable ink is ejected from the ink head onto the reference surface, and the control means While the ink head and the irradiation head are opposed to the reference surface, the UV curable ink is applied by the ink head based on the shape data stored in the storage means while relatively moving along the reference surface. A discharge operation for discharging the reference surface and an irradiation operation for irradiating the UV curable ink layer discharged to the reference surface by the irradiation head with ultraviolet rays are repeatedly performed, and a plurality of shapes corresponding to the shape data are formed on the reference surface. The layers are laminated to form a three-dimensional object composed of a laminate of UV curable ink layers.

According to the present invention configured as described above, the UV curable ink ejected from the ink head can be laminated on the smooth surface member to form a three-dimensional object having a predetermined shape. In particular, a three-dimensional shape is formed one layer at a time by discharging UV curable ink from an ink head, and a plurality of layers are stacked to form a three-dimensional object composed of a laminate of UV curable ink layers. it is possible to form a dimension object at high resolution.

In the three-dimensional object forming apparatus having the above-described configuration, preferably, the control unit performs movement control that causes the interval between the ink head and the irradiation head to follow at a constant interval or a different interval. In this way, the thickness of each layer can be made constant, thick, or thin.

In the three-dimensional object forming apparatus having the above configuration, it is preferable that the three-dimensional object formed on the reference surface can be separated from the smooth surface member or by dissolving the smooth surface member. If it does in this way, it can handle as a component etc. of a 3D object single-piece | unit by peeling or isolate | separating the three-dimensional object formed by lamination | stacking from the smooth surface member.

In the three-dimensional object forming apparatus having the above configuration, preferably, the irradiation power of the ultraviolet rays irradiated from the irradiation head can be variably set. Thereby, the curing speed of the UV curable ink discharged from the ink head can be adjusted, and the thickness of each layer formed in a stacked manner can be adjusted.

In the three-dimensional object forming apparatus configured as described above, preferably, the ink head includes a plurality of color ink heads, and each of the plurality of color ink heads discharges a corresponding color of UV curable ink. Is done. Thereby, a three-dimensional hair object having a color pattern can be freely formed.

On the other hand, in the method for forming a three-dimensional object according to the present invention, an ink head that discharges UV curable ink and an irradiation head that irradiates ultraviolet rays that cure the UV curable ink are laminated with UV curable ink discharged from the ink head. The UV curable ink is ejected onto the reference surface by the ink head and is ejected onto the reference surface by the irradiation head while being relatively moved along the reference surface while facing a smooth surface member having a reference surface. A three-dimensional object comprising a laminate of a UV curable ink layer by repeatedly performing an operation of irradiating the UV curable ink layer with ultraviolet rays and laminating a plurality of layers corresponding to the shape data on the reference surface The shape data of the three-dimensional object to be laminated on the reference surface is converted into the UV curable ink from the ink head. A storage step of storing a plurality of layers based on the thickness of a single layer formed when ejected to the reference surface; and the reference in a state where the ink head and the irradiation head are opposed to the reference surface An ink layer forming step of forming one UV curable ink layer by ejecting UV curable ink onto the reference surface by the ink head based on the shape data stored in the storage means while relatively moving along the surface; , Repeating the ink layer curing step of curing the UV curable ink layer by irradiating the UV curable ink layer discharged to the reference surface by the irradiation head, the ink layer forming step and the ink layer curing step, A stacking step of stacking a plurality of layers corresponding to the shape data on the reference surface to form a three-dimensional object composed of a stack of UV curable ink layers. That.
Accordingly, the UV curable ink ejected from the ink head can be laminated on the smooth surface member to form a three-dimensional object having a predetermined shape. In particular, a three-dimensional shape is formed layer by layer by discharging UV curable ink from an ink head, and a plurality of layers are stacked to form a three-dimensional object composed of a laminate of UV curable ink layers. Dimensional objects can be formed with high resolution.

In the three-dimensional object forming method having the above configuration, preferably, in the ink layer curing step, the irradiation head is moved so as to follow the movement of the ink head at a constant interval or a different interval with respect to the ink head. Then, the UV curable ink layer ejected on the reference surface is irradiated with ultraviolet rays to cure the UV curable ink layer. In this way, the thickness of each layer can be made constant, thick, or thin.

In the three-dimensional object forming method configured as described above, preferably, the three-dimensional object formed on the reference surface in the stacking step is separated from the smooth surface member or separated by dissolving the smooth surface member. Process. If it does in this way, it can handle as a component etc. of a 3D object single-piece | unit by peeling or isolate | separating the three-dimensional object formed by lamination | stacking from the smooth surface member.

In the three-dimensional object forming method having the above configuration, preferably, the irradiation power of the ultraviolet rays irradiated from the irradiation head in the ink layer curing step can be variably set. Thereby, the curing speed of the UV curable ink discharged from the ink head can be adjusted, and the thickness of each layer formed in a stacked manner can be adjusted.

In the three-dimensional object forming method having the above-described configuration, preferably, the ink head includes a plurality of color ink heads, and UV curable inks of corresponding colors from the plurality of color ink heads in the ink layer forming step, respectively. Is discharged. Thereby, a three-dimensional hair object having a color pattern can be freely formed.

  According to the three-dimensional object forming apparatus and the three-dimensional object forming method of the present invention, there is an effect that a three-dimensional object can be formed with high resolution using UV curable ink.

  Exemplary embodiments of a three-dimensional object forming apparatus and a three-dimensional object forming method according to the present invention will be explained below in detail with reference to the accompanying drawings.

(Embodiment 1)
FIG. 1 is a configuration diagram showing a three-dimensional object forming apparatus according to Embodiment 1 of the present invention. The three-dimensional object forming apparatus 1 includes an ink head 2 that ejects ultraviolet (UV) curable ink, and a laser head 3 that irradiates the UV curable ink ejected from the ink head 2 with ultraviolet (UV) to be cured. Prepare. In the configuration of the first embodiment, the UV curable ink ejected from the ink head 2 is laminated on the smooth surface member 4 to form a three-dimensional object. For this reason, the smooth surface member 4 is formed of a material (for example, a plastic material) into which the UV curable ink does not permeate.

  The ink head 2 and the laser head 3 are moved in the main scanning direction in the X-axis direction, and the smooth surface member 4 is moved in the sub-scanning direction in the Y-axis direction orthogonal to the X-axis. These movements are performed using a motor (not shown) as a drive source.

  The laser head 3 performs laser irradiation on the UV curable ink after ejection in a form that follows the scanning of the ink head 2 to cure the UV curable ink.

  The control unit 5 controls the ink ejection of the ink head 2, and controls the scanning (relative movement) of the ink head 2, the laser head 3, and the smooth surface member 4 to form a three-dimensional object. . Connected to the control unit 5 are a setting unit 6 for performing various settings and input operations, and a storage unit 7 for storing shape data of the three-dimensional object set by the setting unit 6. The control unit 5 controls the operations of the ink head 2, the laser head 3, and the smooth surface member 4 according to the shape data stored in the storage unit 7 to form a three-dimensional object corresponding to the shape data. The three-dimensional object forming apparatus 1 described above can be easily configured using the basic structure of a general-purpose inkjet printer.

  FIG. 2 is a flowchart showing a procedure for forming a three-dimensional object by ink lamination. First, the control unit 5 performs initial setting (step S1). In this initial setting, the ink head 2 and the smooth surface member 4 are positioned at the origin positions of the X and Y axes.

  Next, the control unit 5 reads the shape data in the storage unit 7, scans the ink head 2 in the X-axis direction according to the shape data, scans the smooth surface member 4 in the Y-axis direction, and discharges UV curable ink, A first layer (lowermost layer) is formed (step S2). Further, the laser head 3 is moved in the same X-axis direction so as to follow the scanning of the ink head 2. After the movement of the laser head 3 in the X-axis direction is completed, the laser head 3 and the ink head 2 are returned to the positions before scanning. In this way, the UV curable ink can be formed with a height of several μm per layer. This is 1/100 the height of the conventional three-dimensional object forming apparatus described above, and a fine shape can be formed with a resolution of 100 times.

  Here, the control unit 5 determines whether or not the formation of the first layer is completed (step S3). If the formation of the first layer has not been completed (step S3: No), the process returns to step S2 and the formation of the first layer is continued. When the formation of the first layer is completed (step S3: Yes), the second and subsequent layers (n + 1th layer) are formed (step S4).

  The formation of the second and subsequent layers (the (n + 1) th layer) is performed in the same manner as the formation of the first layer, and a three-dimensional object can be formed by stacking. Then, it is determined whether the formation of the second and subsequent layers (the (n + 1) th layer) has been completed (step S5). If the formation of the (n + 1) th layer has not been completed (step S5: No), the process returns to step S4 and the formation of the (n + 1) th layer is continued. When the formation of the (n + 1) th layer is completed (step S5: Yes), it is confirmed whether the layer is the final layer (uppermost layer) (step S6). If it is not the last layer (step S6: No), it will return to step S4 and will repeat step S4-S6. In step S6, if it is the final layer (step S6: Yes), the formation of the three-dimensional object is completed, and the series of processes is terminated.

  As described above, each time the three-dimensional object is formed for each layer in step S2 and step S4, the ink head 2 is scanned in the X-axis direction, the smooth surface member 4 is scanned in the Y-axis direction, This is performed by discharging UV curable ink. Then, a three-dimensional object having an arbitrary shape can be formed by stacking the number of layers.

  The three-dimensional object is formed on the smooth surface member 4 by the above process. The smooth surface member 4 can handle the three-dimensional object as a component by releasing the laminated UV curable ink from the formed three-dimensional object. Alternatively, the smooth surface member 4 itself may be dissolved, or a peelable sheet may be provided on the surface of the smooth surface member 4 to peel the sheet from the smooth surface member 4, and then the three-dimensional object may be peeled from the sheet. Good. In addition, the smooth surface member 4 may be dissolved. In this case, a solution in which the laminated UV curable ink does not dissolve and only the smooth surface member 4 dissolves is used.

  Thus, according to the configuration of the first embodiment, the three-dimensional object can be densely formed with high resolution by laminating the UV curable ink on the smooth surface member 4.

(Embodiment 2)
The configuration of the second embodiment of the present invention relates to the control of the laser head 3 described in the first embodiment.

  The laser head 3 performs laser irradiation on the UV-cured ink after ejection in a form that follows the scanning of the ink head 2, and cures the UV-cured ink. The irradiation timing and the power of the irradiation light depend on the setting. It can be changed after the UV curable ink is discharged. That is, by changing the timing of irradiating the laser after discharging the UV curable ink, it is possible to change the cured state of the UV curable ink and adjust the stack height by one discharge.

  FIG. 3 is a flowchart showing a control procedure of the laser head 3. The illustrated example has a configuration in which the timing of laser irradiation by the laser head 3 after the ink curable ink is discharged by the ink head 2 is variable.

  First, it is determined whether or not the layer thickness per layer is a constant value (step S11). When the layer thickness per layer is constant (step S11: Yes), the laser head 3 is caused to follow the ink head 2 at a constant interval L as shown in FIG. 1 (step S12). Thereby, the start time of laser irradiation by the laser head 3 after ejection of the UV curable ink by the ink head 2 can be made constant, and the layer thickness per layer can be made constant.

  On the other hand, when the layer thickness per layer is not constant (step S11: No), the interval between the laser head 3 and the ink head 2 is changed. When the layer thickness is increased (step S13: Yes), the interval L between the laser head 3 and the ink head 2 is reduced (step S14). In other words, after the UV curable ink is discharged by the ink head 2, the UV curable ink can be cured before the UV curable ink diffuses to the surroundings by advancing the laser irradiation start time by the laser head 3. Increase the layer thickness.

  Further, when the layer thickness is reduced (step S13: No), the interval L between the laser head 3 and the ink head 2 is increased (step S15). That is, after the UV curable ink is ejected by the ink head 2, the UV curable ink can be cured after the UV curable ink is diffused to some extent by delaying the start timing of the laser irradiation by the laser head 3. Reduce the layer thickness per layer.

  As described above, according to the second embodiment, it is possible to easily change the layer thickness per layer only by changing the following relationship between the ink head 2 and the laser head 3. Further, the layer thickness per layer can be finely adjusted by adjusting the start timing of laser irradiation by the laser head 3 after the ink curable ink is discharged by the ink head 2. As a result, the three-dimensional object can be formed with higher resolution by adjusting the layer thickness per layer.

  In the above description, the irradiation power of the laser beam is made constant and the follow-up relationship between the ink head 2 and the laser head 3 is variable. The curing state of the UV curable ink can also be changed by controlling the irradiation power of the laser light. The stronger the laser beam irradiation power, the faster the UV curable ink cures, and the lower the laser beam irradiation power, the slower the UV curable ink cures. Further, the following relationship between the ink head 2 and the laser head 3 can be varied, and the laser beam irradiation power can also be varied.

  Next, specific examples of the three-dimensional object formed by the configuration described in each of the above embodiments will be described. FIG. 4 is a diagram illustrating a micro component that is an example of a three-dimensional object. As shown in the drawing, by laminating UV curable ink on the smooth surface member 4, it is possible to form the micro component 10 having the convex portion 10a in part. In the configuration example of FIG. 4, a convex portion 10a is formed by further stacking a predetermined range of UV curable ink. Although not shown, a concave portion can be formed in the component unless the UV curable ink is laminated only in a part of the range. This micro component can be used as a part of components constituting the micro machine.

  FIG. 5 is a diagram illustrating a translucent plate that is an example of a three-dimensional object. As shown in the figure, by forming UV-cured ink on the smooth surface member 4 with a predetermined shape at regular intervals or at irregular intervals, the light transmittance of the protrusion 15a is reduced. A transparent plate 15 can be formed. This translucent plate 15 can be used for the same application as ground glass. The translucent plate 15 is made of a transparent UV curable ink.

  FIG. 6 is a diagram illustrating a Fresnel lens which is an example of a three-dimensional object. As shown in the drawing, the Fresnel lens 20 can be formed by forming a lens portion 20a having a stepped shape at regular intervals on the smooth surface member 4 using UV curable ink. The Fresnel lens 20 is made of UV curable ink having optical transparency.

  Other three-dimensional objects other than the above configuration examples include gears having gears at regular intervals, Braille protrusions, oil paintings with a sense of unevenness, and the like. In the case of oil painting, a configuration may be adopted in which UV curable ink is ejected for each color using a plurality of color ink heads.

(Embodiment 3)
In Embodiment 3 of the present invention, the UV curable ink is cured without using the smooth surface member 4 to form a minute three-dimensional object having a predetermined shape. FIG. 7 is a block diagram showing a three-dimensional object forming apparatus according to Embodiment 3 of the present invention.

  Although not shown, an ink head 2 that is an ink discharge portion is provided in an upper portion of a closed formation space, and a predetermined amount of UV curable ink 30 is discharged and dropped at one time. During the fall of the UV curable ink 30, the laser beam 31 of the laser head 3 is irradiated to cure the UV curable ink 30. The cured UV curable ink 30 becomes a sphere having a diameter of several μm. The discharge control of the UV curable ink 30 in the ink head 2 and the irradiation power of the laser beam 31 from the laser head 3 are controlled by the control unit 5 similar to FIG.

  Further, the irradiation position of the laser beam 31 by the laser head 3 can be moved up and down as shown in the figure, and as in the second embodiment, the irradiation timing of the laser beam 31 after ink ejection is changed to cure the UV curable ink. The state can be adjusted.

  The fine sphere formed using the UV curable ink 30 with the above configuration can be used as a gap material of a liquid crystal panel, for example. FIG. 8 is a side sectional view showing a liquid crystal panel as an application object in which the three-dimensional object formed according to the present invention is used. In the liquid crystal panel 40, spacers 42 are arranged on four sides of a pair of glass plates 41 to hold a liquid crystal body 43 therein. A sphere formed using the UV curable ink 30 is disposed between the pair of glass plates 41, and the interval between the glass plates 41 is maintained. At present, the gap material is formed of gold, silver or the like and is expensive, but the use of plastic containing copper as the UV curable ink 30 can reduce the cost.

  As described above, according to the third embodiment, the UV curable ink is not limited to the configuration in which the UV curable ink is stacked on the smooth surface member 4, and the UV curable ink is ejected and dropped from the ink head 2 in units of one drop. A three-dimensional object having a minute shape can be formed in units of droplets.

  As described above, according to the three-dimensional object forming apparatus and the three-dimensional object forming method, the UV curable ink can be stacked to form the three-dimensional object with high resolution. Further, even a three-dimensional object having a minute shape can be formed with high resolution. In addition, it is not limited to the formation by stacking, and a minute three-dimensional object can be formed in units of one drop by dropping the UV curable ink after discharging.

  In addition, the ink head 2 demonstrated in each said embodiment is good also as a structure provided with the some ink head 2 according to the thing from which the viscosity of the UV curable ink to discharge differs. In order to form a three-dimensional object, a UV curable ink having a high viscosity is used. By preparing a plurality of these viscosities, the higher the viscosity, the higher the stacking height after ejection per layer, and the lower the viscosity, the lower the state of stacking after ejection per layer can be diffused and lowered. .

  The method for forming the three-dimensional object described in the present embodiment is realized by executing a program prepared in advance on a computer such as a personal computer or a workstation provided with the control unit 5. Can do. This program is recorded on a computer-readable recording medium such as a hard disk, a flexible disk, a CD-ROM, an MO, and a DVD, and is executed by being read from the recording medium by the computer. The program may be a transmission medium that can be distributed via a network such as the Internet.

  As described above, the three-dimensional object forming apparatus and the three-dimensional object forming method according to the present invention are useful for forming a precise or minute three-dimensional object, and in particular, a minute or precise part. It is suitable for all devices for forming other three-dimensional objects.

It is a block diagram which shows the three-dimensional target object formation apparatus concerning Embodiment 1 of this invention. It is a flowchart which shows the formation procedure of the three-dimensional target object by ink lamination. 4 is a flowchart showing a control procedure of the laser head 3. It is a figure which shows the micro component which is an example of a three-dimensional target object. It is a figure which shows the semi-transparent board which is an example of a three-dimensional target object. It is a figure which shows the Fresnel lens which is an example of a three-dimensional target object. It is a block diagram which shows the three-dimensional target object formation apparatus concerning Embodiment 3 of this invention. It is a sectional side view which shows the liquid crystal panel as an application object in which the three-dimensional target formed by this invention is used.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 3D object formation apparatus 2 Ink head 3 Laser head 4 Smooth surface member 5 Control part 6 Setting part 7 Storage part

Claims (10)

An ink head that discharges UV curable ink that is cured by irradiation with ultraviolet rays;
An irradiation head for irradiating ultraviolet rays for curing the UV curable ink;
The smooth surface member having a reference surface for stacking the UV curable ink discharged from the ink head is controlled to move relative to the ink head and the irradiation head, and the UV curable ink is discharged from the ink head. And control means for controlling the irradiation of ultraviolet rays by the irradiation head;
Storage means for storing the shape data of the three-dimensional object to be laminated on the reference plane divided into a plurality of layers having a predetermined thickness on the reference plane;
The predetermined thickness constituting each of the plurality of layers is set to a thickness of one layer formed when UV curable ink is ejected from the ink head to the reference surface,
The control means includes
While the ink head and the irradiation head are opposed to the reference surface, the UV curable ink is applied to the reference by the ink head based on the shape data stored in the storage unit while relatively moving along the reference surface. A plurality of layers corresponding to the shape data are formed on the reference surface by repeatedly performing a discharge operation for discharging the surface and an irradiation operation for irradiating the UV curable ink layer discharged to the reference surface by the irradiation head with ultraviolet rays. A three-dimensional object forming apparatus configured to form a three-dimensional object made of a laminate of UV curable ink layers by laminating.   2. The three-dimensional object forming apparatus according to claim 1, wherein the control unit performs movement control to follow an interval between the ink head and the irradiation head at a constant interval or at different intervals.   The three-dimensional object according to claim 1 or 2, wherein the three-dimensional object formed on the reference surface is separable from the smooth surface member or can be separated by dissolving the smooth surface member. Product forming device.   The three-dimensional object forming apparatus according to any one of claims 1 to 3, wherein the irradiation power of ultraviolet rays irradiated from the irradiation head can be variably set.   5. The ink head according to claim 1, wherein the ink head has a plurality of color ink heads, and is configured to eject UV curable inks of corresponding colors from the plurality of color ink heads. The three-dimensional object forming device according to claim 1. A state in which an ink head for discharging UV curable ink and an irradiation head for irradiating ultraviolet light for curing the UV curable ink are opposed to a smooth surface member having a reference surface on which the UV curable ink discharged from the ink head is laminated. And repeatedly moving the UV curable ink to the reference surface by the ink head and irradiating the UV curable ink layer ejected to the reference surface by the irradiation head while moving relatively along the reference surface. A plurality of layers corresponding to the shape data is formed on the reference surface to form a three-dimensional object composed of a laminate of UV curable ink layers,
The shape data of the three-dimensional object to be laminated on the reference surface is divided into a plurality of layers based on the thickness of one layer formed when UV curable ink is ejected from the ink head to the reference surface. A memory process for storing
While the ink head and the irradiation head are opposed to the reference surface, the UV curable ink is applied to the reference by the ink head based on the shape data stored in the storage means while relatively moving along the reference surface. An ink layer forming step of forming one UV curable ink layer by ejecting the ink onto the surface;
An ink layer curing step of curing the UV curable ink layer by irradiating the UV curable ink layer discharged to the reference surface by the irradiation head with ultraviolet rays;
Lamination that repeats the ink layer formation step and the ink layer curing step, and forms a plurality of layers corresponding to the shape data on the reference surface to form a three-dimensional object composed of a laminate of UV curable ink layers. A method for forming a three-dimensional object. In the ink layer curing step, the irradiation head is moved so as to follow the movement of the ink head at a constant interval or a different interval with respect to the ink head, and the UV curable ink layer discharged onto the reference surface The three-dimensional object forming method according to claim 6 , wherein the UV curable ink layer is cured by irradiating ultraviolet rays. Peeled three dimensional object formed on the reference surface in the laminating step from the smooth surface member, or to claim 6 or 7, characterized in that it comprises a separation step of separating by dissolving the smooth surface member The three-dimensional object forming method described. 9. The three-dimensional object forming method according to claim 6 , wherein the irradiation power of ultraviolet rays emitted from the irradiation head in the ink layer curing step can be variably set. 10. The ink head according to claim 6 , wherein the ink head has a plurality of color ink heads, and in the ink layer forming step, a corresponding color of UV curable ink is ejected from the plurality of color ink heads. The three-dimensional object formation method as described in any one.

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