JP6700958B2 - Modeling apparatus and modeling method - Google Patents

Description

  The present invention relates to a modeling apparatus and a modeling method.

In recent years, three-dimensional modeling technology called additive manufacturing (AM), three-dimensional printer, rapid prototyping (RP), etc. has been attracting attention (in this specification, these technologies are collectively referred to as AM technology). AM technology slices three-dimensional shape data of a three-dimensional model to generate a plurality of slice data, and based on the slice data, sequentially stacks and adheres a modeling material in layers to a three-dimensional object (three-dimensional object). It is a technique for producing a product.
In Patent Document 1, an image made of a thermoplastic modeling material is formed by an electrophotographic method, and the image is heated and melted to form one material layer, and then the material layers are sequentially laminated and fixed. Thus, a technique for producing a three-dimensional object has been proposed.

U.S. Patent Application Publication No. 2013/0186558

In the AM technology of Patent Document 1, when a material layer is laminated on a three-dimensional object (hereinafter, an intermediate object) that is being manufactured, the material layer and the surface of the intermediate object are made to have a glass transition temperature (Tg) of the modeling material or higher. It is heating. Thermoplastic materials become viscous at temperatures above the glass transition temperature. Therefore, by heating the material layer to the glass transition temperature or higher, the adhesive force between the material layer and the carrier of the material layer can be strengthened.
However, if the adhesive force between the material layer and the carrier becomes strong, a part of the material layer remains on the carrier instead of being laminated on the intermediate modeling object during lamination, resulting in stacking failure. There is a concern that it will end up.

  The present invention has been made in view of the above-described circumstances, and an object thereof is to reduce the occurrence of stacking faults and to manufacture a three-dimensional object with higher accuracy.

The first aspect of the present invention is
In a modeling apparatus for manufacturing a three-dimensional three-dimensional object by stacking thermoplastic modeling materials carried on a carrier on a stage,
Heating means for heating the laminated surface of the three-dimensional object on the stage,
On the laminating surface of the three-dimensional object on the stage, laminating means for laminating the modeling material carried on the carrier,
Control means for controlling the heating means and the laminating means,
Has
The control means controls the heating means to heat the lamination surface to a softening temperature of the molding material or higher, and to control the lamination surface to stack the molding material at a temperature lower than the softening temperature. A modeling apparatus is provided.

A second aspect of the present invention is
A modeling method using a modeling apparatus for manufacturing a three-dimensional three-dimensional object by stacking a thermoplastic modeling material carried on a carrier on a stage, the method comprising:
A heating step of heating the laminated surface of the three-dimensional object on the stage,
Lamination for laminating the modeling material, which is carried by the carrier and is lower than the softening temperature, on the laminating surface of the three-dimensional object on the stage heated to the softening temperature of the modeling material or higher by the heating step. Process,
The present invention provides a modeling method including:

  According to the present invention, it is possible to reduce the occurrence of stacking defects and manufacture a three-dimensional object with higher accuracy.

The figure which shows typically the whole structure of the modeling apparatus which concerns on embodiment. A figure for explaining a modeling process of a modeling device concerning this embodiment. The figure which shows the modeling apparatus which concerns on 2nd Embodiment typically. The figure which shows the modeling apparatus which concerns on 3rd Embodiment typically. The figure which shows the modeling apparatus which concerns on 4th Embodiment typically. The figure which shows the modeling apparatus which concerns on 5th Embodiment typically. The figure which shows the modeling apparatus which concerns on 6th Embodiment typically. The figure which shows the modeling apparatus which concerns on 7th Embodiment typically. The figure which shows the modeling apparatus which concerns on 8th Embodiment typically. Schematic diagram showing an image forming unit that arranges material layers using an electrophotographic process

Embodiments for carrying out the present invention will be exemplarily described below with reference to the drawings. However, unless otherwise specified, various control procedures, control parameters, target values, etc., such as the dimensions, materials, shapes, and relative positions of the respective members described in the following embodiments, are not included in the present invention. Is not intended to limit the scope of the above.
The present invention relates to a modeling apparatus that employs additive modeling technology (AM technology), that is, a technology that creates a three-dimensional object (three-dimensional object) by laying modeling materials two-dimensionally and stacking them in layers.
As the molding material, various materials can be selected depending on the use, function, purpose, etc. of the three-dimensional object to be manufactured. In the present specification, a material forming a three-dimensional object for modeling is referred to as a "structural material", and a portion formed of the structural material is referred to as a structure. A material forming a support body (for example, a pillar that supports an overhang portion from below) for supporting a structure that is being manufactured is referred to as a “support material”. Further, when it is not necessary to distinguish between the two, the term "modeling material" is simply used. As the structural material, for example, a thermoplastic resin such as PE (polyethylene), PP (polypropylene), ABS, PS (polystyrene) can be used. Further, as the support material, a material having thermoplasticity and water solubility can be preferably used in order to facilitate the removal from the structure. Examples of the support material include sugar, polylactic acid (PLA), PVA (polyvinyl alcohol), PEG (polyethylene glycol), and the like.

Further, in the present specification, digital data obtained by slicing the three-dimensional shape data of the three-dimensional model to be molded into a plurality of layers along the stacking direction is referred to as “slice data”. The slice data is generated by adding information such as support material data as necessary. A layer formed of a modeling material based on slice data is called a "material layer". This material layer is composed of an image formed by one or a plurality of image forming sections (image forming means), and the image formed by each image forming section is called a "material image". In other words, the “material layer” is a layer of particles formed by combining one or more material images, depending on the type of modeling material used.
In addition, the three-dimensional model to be produced using the modeling apparatus (that is, the 3D model given to the modeling apparatus)
The three-dimensional object represented by the three-dimensional shape data) is referred to as a "modeling object". A three-dimensional object (three-dimensional object) produced (output) by the modeling apparatus is referred to as a “modeled object”. In the case where the modeled object includes the support body, the part excluding the support body becomes the “structure” that constitutes the modeled object. A three-dimensional object (laminate) on a stage that is in the process of being manufactured by using a modeling apparatus is called an "intermediate model".

[Characteristic Configuration and Modeling Method of this Embodiment]
The characteristic configuration of the modeling apparatus and the modeling method according to the embodiment of the present invention will be described below together with the overall configuration of the modeling apparatus. FIG. 1 is a diagram schematically showing the overall configuration of a modeling apparatus according to this embodiment. 2A to 2D are views for explaining a modeling process of the modeling apparatus according to the present embodiment. 2A shows a transfer step of the material layer M and a heating step of the intermediate shaped article S, FIG. 2B shows a transfer step of the material layer M, and FIG. 2C shows a stacking step of the material layer M. 2D shows the fixing step of the material layer M.

As shown in FIG. 1, the modeling apparatus 1 roughly includes a control unit U1, a material layer forming unit U2, and a laminating unit U3.
The control unit U1 is a unit responsible for a process of generating slice data of a plurality of layers from three-dimensional shape data of a modeling target, control of each part of the modeling apparatus 1 such as the material layer forming unit U2 and the laminating unit U3. The material layer forming unit U2 is a unit that forms a material layer M made of the modeling materials Ma and Mb using an electrophotographic process. The material layer forming unit U2 automatically detects the types of the modeling materials Ma and Mb to be set and sends the modeling material information to the control unit U1, or the operator directly inputs the information to the control unit U1. Recognize the type of modeling material. The laminating unit U3 is a unit for producing a modeled object by sequentially laminating and fixing a plurality of material layers formed by the material layer forming unit U2. The modeling apparatus 1 has a configuration in which the closest distance between the material layer forming unit U2 and the laminating unit U3 can be changed. In the present embodiment, the material layer forming unit U2 is movable in the horizontal direction in FIG. It is configured.

  The material layer forming unit U2 will be specifically described below. First, based on the slice data generated by the control unit U1, material images are formed in the image forming units 10a and 10b. The material images formed by the image forming units 10a and 10b are transferred to the intermediate carrier 111 by the transfer devices 104a and 104b, respectively, and become the material layer M. When the material layer M is formed on the intermediate carrier 111, the material layer forming unit U2 moves to the stacking unit U3 side, and the intermediate carrier 111 and the second intermediate carrier 20 come into contact with each other. An electric field is formed between the intermediate carrier 111 and the second intermediate carrier 20 by a high-voltage power source (not shown), so that the material layer M on the intermediate carrier 111 is electrostatically transferred to the second intermediate carrier 20. Are transcribed (FIG. 2A).

  While the material layer M transferred from the material layer forming unit U2 to the second intermediate carrier 20 of the laminating unit U3 is conveyed to the laminating position N as it is, the intermediate modeling object S on the stage 23 has its laminating surface Sa Is heated by the heater 22 until the temperature reaches the target temperature (FIGS. 2A and 2B). A feature of this embodiment is that the target temperature is set to be equal to or higher than the softening temperature of each modeling material. The softening temperature of the modeling material is set based on the type of the modeling material recognized by the control unit U1. Specifically, the control unit U1 may set it by referring to a table showing the relationship between the material type and the softening temperature. The table may be held by the control unit itself or may be held outside the control unit. Whether or not the laminated surface Sa has reached the target temperature may be determined based on the relationship between the heater temperature and the heating time required to heat the laminated surface Sa to the target temperature, which has been measured in advance. You may judge by monitoring the laminated surface Sa with a total. Further, when the material layer M is transferred from the material layer forming unit U2 to the second intermediate carrier 20, the material layer forming unit U2 is not affected by the heat generated in the laminating unit U3. Move to the far side (Fig. 2B).

Here, the softening temperature is the temperature dependence of the storage elastic modulus and the loss elastic modulus in the shear direction of a molded body obtained by press-molding an aggregate of particles of a material (modeling material) into a cylindrical shape having a diameter of 10 mm and a thickness of 1 mm. The temperature at which the storage elastic modulus is 10 MPa when measured as follows. That is when the temperature was measured at a rate of 2° C./min by a rotary rheometer with an angular frequency of 1 Hz. Further, the stacking position N is a position where the stacking of the material layers M (step of stacking the material layers on the intermediate shaped article S) is performed, and in the configuration of FIG. 1, the second intermediate carrier 20 and the stage 23 are formed by the material layers. A portion in contact with M and the intermediate shaped article S is the stacking position N.
When the material layer M carried by the second intermediate carrier 20 reaches the stacking position N, the material layer M on the second intermediate carrier 20 comes into contact with the stacking surface Sa of the intermediate model S, and the intermediate modeled product. It is transferred to S and laminated (FIG. 2C).

At this time, since the laminated surface Sa of the intermediate shaped article S heated to the softening temperature or higher has a viscosity, a strong adhesive force Mf′ is generated between the laminated surface Sa and the material layer M. On the other hand, the temperatures of the second intermediate carrier 20 and the material layer M are set to be lower than the softening temperature (above room temperature), and the material layer itself does not become viscous. The adhesive force Mf between the material 20 and the material layer M has a relatively low value. In this way, the laminated surface Sa of the intermediate shaped article S is heated to the softening temperature or higher, and the temperatures of the second intermediate carrier 20 and the material layer M are set to lower than the softening temperature. The upper material layer M can be more reliably transferred onto the intermediate shaped article S.
When the material layer M is heated to the softening temperature or higher, the material layer M becomes viscous, so that the adhesive force Mf between the second intermediate carrier 20 and the material layer M becomes large, and the material on the second intermediate carrier 20 becomes large. A part of the layer M is not transferred onto the intermediate molded article S, and a stacking failure that remains on the second intermediate carrier 20 is likely to occur.
When the material layer M is stacked on the intermediate molded article S on the stage 23, the stage 23 moves to a position where the heater 22 becomes a heating region, and the portion of the material layer M stacked on the intermediate molded article S is moved by the heater 22. It is melted and fixed to the intermediate shaped article S (FIG. 2D).

As described above, the present embodiment is characterized in that the material layer M having a temperature lower than the softening temperature is transferred and laminated on the intermediate shaped article S having the temperature of the laminating surface Sa equal to or higher than the softening temperature. As a result, it is possible to suppress the occurrence of stacking failure in which the modeling material remains on the second intermediate carrier 20, and it is possible to manufacture the modeled object with higher accuracy.
Below, the specific example of the modeling apparatus to which this invention can be applied suitably is demonstrated using 1st-8th embodiment. In any of the first to eighth embodiments, the same effects as those described above can be obtained. In addition, the same code|symbol is attached|subjected about the same component in the above-mentioned embodiment and 1st-8th embodiment.

<First Embodiment>
The first embodiment will be described below.
First, the configuration of the control unit U1 of this embodiment will be described.
[Controller unit]
As shown in FIG. 1, the control unit U1 has, as its functions, a three-dimensional shape data input unit U10, a slice data calculation unit U11, a material layer forming unit control unit U12, a stacking unit control unit U13, and the like.

  The three-dimensional shape data input unit U10 has a function of receiving three-dimensional shape data of a modeling target from an external device (for example, a personal computer). As the three-dimensional shape data, data created and output by a three-dimensional CAD, a three-dimensional modeler, a three-dimensional scanner or the like can be used. The file format is not limited, but the STL (StereoLithography) file format can be preferably used, for example.

The slice data calculation unit U11 slices the modeling object represented by the three-dimensional shape data at a predetermined pitch to calculate the cross-sectional shape of each layer, and based on the cross-sectional shape, the material layer forming unit U2 uses it for image formation. It has a function of generating data (slice data). Further, the slice data calculation unit U11 analyzes the three-dimensional shape data or the cross-sectional shapes of the upper and lower layers to determine the presence or absence of an overhang portion (a portion that floats in the air), and is used to form a support body as necessary. Generate slice data containing the data.
The material layer forming unit U2 of the present embodiment is capable of forming a material layer using a plurality of types of modeling materials. Therefore, it is possible to form the material layer corresponding to the slice data including the data for forming the material image made of each modeling material. As the file format of the slice data, for example, multi-valued image data (each value represents the type of modeling material) or multi-plane image data (each plane corresponds to the type of modeling material) can be used.

  The material layer forming unit controller U12 has a function of controlling the material layer forming process in the material layer forming unit U2 based on the slice data generated by the slice data calculator U11. As will be described later, the control unit U1 also controls the developing device so that the particles of the modeling material forming the material image are arranged so as to satisfy a predetermined condition. Further, the laminating unit controller U13 has a function of controlling the laminating process in the laminating unit U3.

Although not shown, the control unit U1 also includes an operation unit, a display unit, and a storage unit. The operation unit has a function of receiving an instruction from the user. For example, it is possible to turn on/off the power supply, various settings of the device, and input of operation instructions. The display unit has a function of presenting information to the user. For example, it is possible to present various setting screens, error messages, operating conditions, and the like. The storage unit has a function of storing three-dimensional shape data, slice data, various set values, and the like.
In terms of hardware, the control unit U1 is configured by a computer including a CPU (central processing unit), memory, auxiliary storage device (hard disk, flash memory, etc.), input device, display device, and various I/Fs. You can Each of the functional units U10 to U13 described above is realized by the CPU reading and executing a program stored in an auxiliary storage device or the like and controlling necessary devices. However, some or all of the above-described functional units may be configured by a circuit such as an ASIC or FPGA, or may be executed by another computer using a technology such as cloud computing or grid computing. ..

[Material layer forming unit]
Next, the configuration of the material layer forming unit U2 will be described.
The material layer forming unit U2 is a unit that forms a material layer made of a modeling material using an electrophotographic process. The electrophotographic process is a method of forming a desired material image on an image carrier (photoreceptor) as follows. First, the image carrier is uniformly charged, and the charged image carrier is exposed according to the image information to form a latent image (electrostatic latent image) according to the image information on the image carrier. Then, the developer particles (modeling material particles) are attached to the latent image portion on the image carrier to form a developer image on the image carrier. A desired material image is formed on the image bearing member by such a series of processes.

As shown in FIG. 1, the material layer forming unit U2 includes a first image forming unit 10a, a second image forming unit 10b, and a transfer unit 11, and is movable in the horizontal direction together with the material layer forming unit U2. There is.
The first image forming unit 10a is an image forming unit that forms a material image by using the modeling material Ma. The first image forming unit 10a includes an image carrier 100a, a charging device 101a that charges the image carrier 100a, an exposure device 102a that exposes the image carrier 100a to form a latent image, and develops the latent image with a molding material Ma. Developing device 103 for forming a material image on the surface of the image carrier 100a
a. The first image forming unit 10a also includes a cleaning device 105a that cleans the image carrier 100a.

The second image forming unit 10b is an image forming unit for forming a material image using the modeling material Mb. The second image forming unit 10b includes an image carrier 100b, a charging device 101b, an exposure device 102b, a developing device 103b, and a cleaning device 105b, like the first image forming unit 10a.
The transfer unit 11 includes transfer devices 104a and 104b, an intermediate carrier 111, a second cleaning device 112, and an image detection sensor 113. The material images formed by the image forming units 10a and 10b are transferred to the intermediate carrier 111 by the transfer devices 104a and 104b, and material layers are formed.

  In the present embodiment, a structural material made of a thermoplastic resin or the like is used as the modeling material Ma, and a thermoplastic and water-soluble support material is used as the modeling material Mb. In the case of a cross section that does not have an overhang portion and does not require a support body, the image forming unit 10b does not perform image formation. In that case, the material layer is formed only by the material image of the structural material. The diameter of the particles of each modeling material is preferably 5 μm or more and 50 μm or less.

These image forming units 10a and 10b are arranged along the surface of the intermediate carrier 111 in the transport direction of the intermediate carrier 111.
In FIG. 1, the image forming unit 10a using the structural material is arranged on the upstream side of the image forming unit 10b using the support material in the rotating direction of the intermediate carrier 111 (the moving direction of the belt surface). The arrangement order of the forming portions is not limited to this, and can be set appropriately. Further, the number of image forming units is not limited to two, and one or a plurality of image forming units may be provided. That is, the number of image forming units can be set to an appropriate number according to the specifications of the modeling apparatus and the type and number of modeling materials used.

Hereinafter, the configuration of each part of the material layer forming unit U2 will be described in detail. However, in the description common to the image forming units 10a and 10b, the subscripts a and b added to the reference numerals of the respective constituent members are omitted for convenience of description, and the image forming unit 10 and the image carrier 100 are described. In some cases.
FIG. 10 is a diagram schematically showing a configuration of the image forming unit 10 in which material layers are arranged by using an electrophotographic process.
(Image carrier)
The image carrier 100 is a member for carrying a latent image. In this embodiment, a photoconductor drum in which a photoconductor layer having photoconductivity is formed on the outer peripheral surface of a metal cylinder such as aluminum is used. As the photoconductor, an organic photoconductor (OPC), an amorphous silicon photoconductor, a selenium photoconductor, or the like can be used, and the type of the photoconductor may be appropriately selected depending on the use of the modeling apparatus and the required performance. The image carrier 100 is rotatably supported by a frame (not shown), and is rotated counterclockwise in FIG. 10 at a constant speed by a drive source (not shown) when a material image is formed.

(Charging device)
The charging device 101 is a charging unit for uniformly charging the surface of the image carrier 100. In this embodiment, a non-contact charging method using corona discharge is used, but another charging method such as a roller charging method in which a charging roller is brought into contact with the surface of the image carrier 100 may be used.
(Exposure device)
The exposure device 102 is an exposure unit that exposes the image carrier 100 according to image information (slice data) and forms a latent image on the surface of the image carrier 100. The exposure apparatus 102 includes, for example, a light source such as a semiconductor laser or a light emitting diode, a scanning unit having a polygon mirror that rotates at high speed, and an optical member such as an imaging lens.

(Developer)
The developing device 103 uses a well-known contact one-component developing method, and supplies a modeling material (here, particles of a structural material or a support material) as a developer to the image carrier 100 to visualize the latent image. Is. In this specification, the image visualized by the developer on the image carrier 100 is referred to as a material image.
The developing device 103 preferably has a so-called developing cartridge structure and is detachably attached to the material layer forming unit U2. As a result, it is possible to easily replenish and change the developer (structural material, support material) by replacing the cartridge. Further, the image carrier 100, the developing device 103, the cleaning device 105, and the like may be integrated into a cartridge (so-called process cartridge) so that the image carrier itself can be replaced. When the wear and life of the image carrier 100 are particularly problematic due to the type, hardness, and particle size of the structural material and support material, the process cartridge configuration is more practical and convenient.

(Cleaning device)
The cleaning device 105 is a unit that collects particles of the modeling material that are not transferred and remains on the image carrier 100, and cleans the surface of the image carrier 100. In the present embodiment, the blade type cleaning device 115 in which the particles are scraped off by the cleaning blade that is brought into contact with the image carrier 100 in the counter direction is used, but a brush type or electrostatic adsorption type cleaning device may be used. Good.
(Transfer device)
The transfer device 104 provided in the transfer unit 11 is a transfer unit that transfers the material image formed on the peripheral surface of the image carrier 100 to the surface of the intermediate carrier 111. The transfer device 104 is disposed on the opposite side of the image carrier 100 with the intermediate carrier 111 interposed therebetween, and when a voltage having a polarity opposite to the charging polarity of the material image on the image carrier 100 is applied, electrostatic transfer is performed. The material image is transferred to the intermediate carrier 111. Transfer from the image carrier 100 to the intermediate carrier 111 is also referred to as primary transfer. Although the transfer method using corona discharge is used in this embodiment, a transfer method other than the roller transfer method or the electrostatic transfer method may be used.

(Intermediate carrier)
The intermediate carrier 111 is a carrier (conveyer) to which the material image formed in each image forming unit 10 is transferred. After the material image formed of the structural material is transferred from the first image forming unit 10a to the intermediate carrier 111, the position of the material image is aligned with that of the intermediate carrier 111, and the image on the downstream side of the first image forming unit 10a is aligned. The material image formed of the support material is transferred from the two-image forming unit 10b. As a result, one material layer (one layer) is formed on the surface of the intermediate carrier 111.
The intermediate carrier 111 is an endless belt member formed of a material such as resin or polyimide, and is stretched around a plurality of rollers 114 and 115 as shown in FIG. A tension roller may be provided in addition to the rollers 114 and 115 so that the tension of the intermediate carrier 111 can be adjusted. At least one of the rollers 114 and 115 is a driving roller, and when the material layer is formed, the intermediate carrier 111 is rotated clockwise in FIGS. 1 and 10 by the driving force of a driving source (not shown). The roller 114 is a roller that forms a secondary transfer portion with the second intermediate carrier 20 of the stacking unit U3.

(Second cleaning device)
The second cleaning device 112 is means for cleaning the modeling material and the like attached to the surface of the intermediate carrier 111. In the present embodiment, a blade type cleaning device in which the material is scraped off by a cleaning blade that is in contact with the intermediate carrier 111 in the counter direction is used, but a brush type or electrostatic attraction type cleaning device may be used. ..
(Image detection sensor)
The image detection sensor 113 is a detection unit that reads the position of the material layer carried on the surface of the intermediate carrier 111 and the concentration of the modeling material particles. The detection result of the image detection sensor 113 is used for alignment of material layers, timing control with the laminating unit U3, abnormality detection of material layers, and the like. It should be noted that the abnormality of the material layer means that the material layer is not a desired image, there is no image, variation in thickness, or positional deviation of the image exceeds an allowable value.
The concentration of the modeling material particles in the material layer can be read by the image detection sensor 113 having a function of detecting the projected area ratio per unit volume of the material layer. Specifically, the image detection sensor 113 may have a function of performing image processing on a grayscale image obtained by illuminating the material layer.

[Lamination unit]
Next, the configuration of the laminated unit U3 will be described.
The stacking unit U3 is a unit that receives the material layers formed by the material layer forming unit U2 from the intermediate carrier 111, and sequentially stacks and fixes the material layers to form a modeled object.
As shown in FIG. 1, the stacking unit U3 includes a second intermediate carrier 20, an image detection sensor 21, a heater 22, a stage 23, a cooling device 24, and a third cleaning device 25. Hereinafter, the configuration of each part of the laminated unit U3 will be described in detail.

(Second intermediate carrier)
The second intermediate carrier 20 is a carrier that receives the material layer formed by the material layer forming unit U2 from the intermediate carrier 111 and carries and carries the material layer to the stacking position N.
The second intermediate carrier 20 is a cylindrical drum member (cylindrical member) made of a material such as resin, polyimide, or metal such as stainless steel. The second intermediate carrier 20 rotates counterclockwise in FIG. 1 by the driving force of a driving source (not shown). It is desirable to coat the surface of the second intermediate carrier 20 with a fluorine resin such as PTFE or PFA in order to reduce the adhesive force Mf with the material layer. Here, PTFE is polytetrafluoroethylene and PFA is a tetrafluoroethylene perfluoroalkyl vinyl ether copolymer.
(Second image detection sensor)
The second image detection sensor 21 is a detection unit that detects the position of the material layer carried on the surface of the second intermediate carrier 20 and the concentration of the molding material particles. The second image detection sensor 21 is installed downstream of the contact position between the intermediate carrier 111 and the second intermediate carrier 20 and upstream of the stacking position N in the rotation direction of the second intermediate carrier 20. There is.
The detection result of the second image detection sensor 21 is used for alignment of material layers, control of transport timing to the stacking position N, and the like.

(heater)
The heater 22 is a temperature control unit that controls the temperature of the intermediate modeled article S and the material layer M transferred to the laminated surface Sa of the intermediate modeled article S. As the heater 22, for example, a ceramic heater, a halogen heater or the like can be used. Further, it is desirable that the temperature of the heater 22 is set to be equal to or higher than the temperature at which the material layer M melts. In addition, by adjusting the distance between the heater 22 and the intermediate shaped article S, the temperature of the stacking surface Sa of the intermediate shaped article S can be controlled. As a result, after the material layer M is transferred to the intermediate model S, the heater 22 is brought close to the intermediate model S, whereby the material layer M can be melted and fixed to the intermediate model S (FIG. 2D). Here, the distance between the heater 22 and the intermediate molded article S on the stage 23 may be adjusted by moving at least one of the heater 22 and the stage 23 in the vertical direction. Further, in the present embodiment, as described later, the stage 23 is moved to the heating region of the heater 22 to heat the intermediate modeled article S and the material layer M transferred to the laminated surface Sa of the intermediate modeled article S. However, the present invention is not limited to this. It suffices that the stage 23 and/or the heater 22 be arranged so as to be movable between a position when stacking is performed and a position when heating by the heater 22 is performed.

(stage)
The stage 23 is a flat base on which the material layers M are stacked. The stage 23 is driven in the vertical direction and the horizontal direction in FIG. 1 by a driving means such as an actuator (not shown) (a normal line and a tangent line at the stacking position N shown in FIG. 1 on the outer peripheral surface of the cylindrical second intermediate carrier 20). Direction). By sandwiching the material layer M carried and conveyed to the stacking position N between the stage 23 and the second intermediate carrier 20, the viscosity of the stacking surface Sa of the intermediate shaped article S causes the stage from the second intermediate carrier 20 side. The material layer M can be transferred to the 23 side.

It is preferable that a solvent-soluble material or a temperature-sensitive adhesive whose adhesiveness and non-adhesiveness change in response to temperature changes is previously installed on the surface of the stage 23. In this embodiment, an example in which a thermoplastic resin (thermoplastic material) Ms is arranged as a solvent-soluble material is shown. When the thermoplastic resin Ms is provided on the surface of the stage 23, the molded article can be removed from the stage 23 more easily by removing the thermoplastic resin Ms when the modeling is completed. Here, the thermoplastic resin Ms is preferably the same material as the support material having thermoplasticity and water solubility, and the material layer forming unit U2 forms the material layer M of only the support material and stacks it on the stage 23. You may produce by that. Further, since the first material layer M is directly transferred onto the thermoplastic resin Ms, when laminating the first material layer M, the surface of the thermoplastic resin Ms is It is desirable to set the softening temperature of Ms or higher.
Further, when the temperature-sensitive adhesive is provided on the surface of the stage 23, when the modeling is completed, the adhesive force of the temperature-sensitive adhesive is eliminated by setting the temperature equal to or lower than the preset switching temperature. The model can be removed more easily. As the temperature-sensitive adhesive, a temperature-sensitive adhesive sheet Intelimer (registered trademark) tape manufactured by Nitta Co., Ltd. can be used. Here, in the present embodiment, the second intermediate carrier 20, the heater 22, and the stage 23 constitute a laminating means for laminating the material layers M.

(Cooling system)
The cooling device 24 is a device for cooling the second intermediate carrier 20. The second intermediate carrier 20 comes into contact with the intermediate modeled article S heated by the heater 22 through the material layer M, and thus the surface thereof is likely to be heated. Further, since the heaters 22 are arranged so as to be adjacent to each other, the temperature of the heaters 22 is easily raised by the heat of the heaters 22. When the temperature of the second intermediate carrier 20 becomes equal to or higher than the softening temperature of the material layer M, there is a concern that stacking failure may occur. Therefore, it is desirable that the second intermediate carrier 20 be cooled by the cooling device 24. Further, by cooling the second intermediate carrier 20 with the cooling device 24, it is possible to suppress the influence of heat in the stacking unit U3 on the material layer forming unit U2.
In the present embodiment, the cooling device 24 is installed downstream of the stacking position N in the rotation direction of the second intermediate carrier 20, but the invention is not limited to this. That is, the cooling device 24 is not particularly limited in its installation position as long as it can cool the second intermediate carrier 20 so that the temperature of the second intermediate carrier 20 does not exceed the softening temperature of the material layer M. Not a thing. Further, the cooling device 24 is preferably air-cooled by a compressor, a fan or the like, but the cooling system is not particularly limited, and may be, for example, a water-cooled system from inside the second intermediate carrier 20 with cooling water.
In addition, in order to suppress the heat of the heater 22 from being directly applied to the second intermediate carrier 20, it is also preferable to provide a heat insulating member between the second intermediate carrier 20 and the heater 22.

(Third cleaning device)
The third cleaning device 25 is a device for removing from the second intermediate carrier 20 contaminants adhering to the second intermediate carrier 20 and modeling materials that have not been stacked on the intermediate modeled article S due to lack of concentration or the like. is there. In the third cleaning device 25 of the present embodiment, the cleaning blade that is in contact with the surface of the second intermediate carrier 20 on which the material layer M is carried and carried (carrying surface) in the counter direction scrapes off contaminants and modeling materials. Uses a blade method. However, the present invention is not limited to this, and a brush type or electrostatic adsorption type cleaning device may be used. Further, in FIG. 1, the third cleaning device 25 is installed downstream of the cooling device 24 in the rotation direction of the second intermediate carrier 20, but not limited to this, as long as it is downstream of the stacking position N. It may be installed upstream of the cooling device 24.

  These units U1 to U3 may be housed in different housings or may be housed in a single housing. The configuration in which the units U1 to U3 are provided in separate casings allows easy combination and replacement of the units depending on the application of the modeling apparatus, required performance, modeling material to be used, installation space, etc. Therefore, there is an advantage that the flexibility and convenience of the device configuration can be improved. On the other hand, the configuration in which all the units are housed in one housing has advantages such as downsizing of the entire apparatus and cost reduction.

<Second Embodiment>
The second embodiment will be described below.
FIG. 3 is a diagram schematically showing the modeling apparatus according to the present embodiment.
In the present embodiment, the heater 26 as a heating means is formed in a roller shape having elastic rubber on the surface. A heating unit such as a halogen heater (not shown) is incorporated inside the roller and is the same as the first embodiment except that it rotates counterclockwise in FIG. In the present embodiment, the rotary shaft of the heater 26 is rotatably supported by the modeling apparatus body, and the stage 23 moves in the horizontal direction of FIG. It is configured to be heated by the heater 26.

The elastic rubber layer on the surface of the heater 26 is brought into contact with the laminating surface Sa of the intermediate shaped article S to heat the laminating surface Sa of the intermediate shaped article S to a softening temperature or higher. At this time, while the elastic rubber layer of the heater 26 and the laminated surface Sa of the intermediate shaped article S are kept in contact with each other, the rotating operation of the heater 26 and the horizontal moving operation of the stage 23 are performed, The laminated surface Sa of the intermediate shaped article S is heated over the entire area.
It is desirable that the surface of the elastic rubber layer of the heater 26 be coated with a fluorine-based resin, so that the adhesive force generated between the laminated surface Sa of the intermediate shaped article S and the heater 26 can be suppressed. Further, the elastic rubber layer of the heater 26 is sufficiently brought into contact with the lamination surface Sa of the intermediate molded article S to press the lamination surface Sa of the intermediate molded article S, so that the inside of the intermediate molded article S and the lamination surface Sa of the intermediate molded article S are Bubbles existing between and can be removed.

<Third Embodiment>
The third embodiment will be described below.
FIG. 4 is a diagram schematically showing the modeling apparatus according to this embodiment.
In the present embodiment, as shown in FIG. 4, as a heating means, a high temperature tank 27 is installed so as to surround the stage 23, and a hot air generator 28 that generates hot air and sends it into the high temperature tank 27 is installed. The third embodiment is the same as the first embodiment except that it is described.

By configuring the inside of the high-temperature tank 27 at the target temperature by the hot air generated from the hot air generator 28, the temperature of the stacking surface Sa of the intermediate shaped article S can always be equal to or higher than the softening temperature of the intermediate shaped article S. it can. Further, by keeping the inside of the high temperature tank 27 at a constant temperature, the ambient temperature around the intermediate shaped article S can be kept constant, so that the temperature unevenness in the intermediate shaped article S can be reduced. As a result, it is possible to prevent the intermediate molded product S from being distorted (deformed) due to the temperature unevenness in the intermediate molded product S and from being cracked in the intermediate molded product S due to the distortion.
Further, as shown in FIG. 4, an opening 27a is provided in the upper part of the high temperature tank 27, and the material layer can be transferred from the second intermediate carrier 20 to the stage 23 through the opening 27a. ..
In addition, the heater 22 of the first embodiment is added to the heating unit including the above-described high temperature tank 27 shown in FIG. May be heated by the heater 22.

<Fourth Embodiment>
The fourth embodiment will be described below.
FIG. 5 is a diagram schematically showing the modeling apparatus according to this embodiment.
In the present embodiment, apart from the heater 22, the second heater 29 is provided as a temperature control means for controlling the temperature of the material layer M transferred to the laminated surface Sa of the intermediate shaped article S, except that the second heater 29 is provided. It is similar to that of the first embodiment. In the second heater 29, for example, a ceramic heater, a halogen heater, etc. are built in, and the surface 29a on the stage 23 side is polished. The surface 29a of the second heater 29 is a contact surface when the second heater 29 comes into contact with the intermediate shaped article S on the stage 23, as described later. The laminated surface 29a of the second heater 29 is preferably polished so that the average roughness is 1 μm or less. In the present embodiment, the temperature of the heater 22 is equal to or higher than the softening temperature of the material layer M and lower than the temperature at which the material layer M melts, and the temperature of the second heater 29 is set to be equal to or higher than the temperature at which the material layer M melts. It is desirable that

The process of heating the intermediate shaped article S on the stage 23 with the second heater 29 peculiar to this embodiment will be described below.
First, when the material layer M is stacked on the stacking surface Sa of the intermediate molded article S on the stage 23, the stage 23 moves to the right in the horizontal direction in FIG. 5 until it is located below the second heater 29. After the stage 23 is positioned below the second heater 29, the second heater 29 descends and comes into contact with the material layer M on the stage 23, so that the material layer M is heated and/or pressurized to form the intermediate modeling object S. Fixed.
When the material layer M is fixed to the intermediate shaped article S, the heating operation of the second heater 29 is stopped, and the temperature of the stacking surface Sa of the intermediate shaped article S drops to a temperature below the temperature at which the material layer M melts. The second heater 29 moves upward and separates from the intermediate modeling object S to which the material layer M is fixed. In addition, in order to lower the temperature of the second heater 29, means for cooling the second heater 29 may be installed. The cooling method at this time may be an air cooling method or a water cooling method, and is not particularly limited.

Further, it is desirable that the surface 29a of the second heater 29 be coated with a release agent such as fluororesin.
In addition, it is preferable that the pressure sensors be installed at a plurality of positions on the surface of the second heater 29 on the back side of the front surface 29a. Thereby, when the second heater 29 pressurizes the material layer M laminated on the intermediate molded article S on the stage 23, the measurement values of the respective pressure sensors are fed back to the laminating unit control unit U13, so that the material layer The M and the intermediate shaped product S can be uniformly pressed. As a result, it is possible to manufacture a more accurate modeled object.

<Fifth Embodiment>
The fifth embodiment will be described below.
FIG. 6 is a diagram schematically showing the modeling apparatus according to the present embodiment.
In the present embodiment, as shown in FIG. 6, the stacking unit U3 includes the third intermediate carrier 30, the preheating heater 31, the cooling device 34, the fourth cleaning device 36, the image detection sensor 21, the heater 22, and the stage 23. It is similar to the first embodiment except that it is provided. Hereinafter, the configuration of each part of the laminated unit U3 specific to this embodiment will be described in detail.

(Third intermediate carrier)
The third intermediate carrier 30 is an endless belt member formed of a metal such as SUS (stainless steel), a resin, a material such as polyimide, and as shown in FIG. It is stretched around a metal roller 35. Here, the elastic rollers 32 and 33 have an elastic rubber layer made of urethane or silicone. The metal roller 35 is a roller made of metal such as SUS or aluminum. Further, at least one of the elastic rollers 32 and 33 and the metal roller 35 is a drive roller.

The elastic roller 32 is a roller that is arranged at a position facing the roller 114 of the material layer forming unit U2 and forms a secondary transfer portion with the roller 114. Further, as shown in FIG. 6, when the material layer M formed in the material layer forming unit U2 is electrostatically (electrically) transferred to the third intermediate carrier 30, the high voltage power source 37 is applied to the elastic roller 32. The voltage is applied by.
Further, in this embodiment, the elastic roller 32 is rotatably supported by the main body of the modeling apparatus, and the material layer forming unit U2 is configured to be movable in the horizontal direction in FIG. When the material layer M is transferred from the intermediate carrier 111 of the material layer forming unit U2 to the third intermediate carrier 30 of the laminating unit U3, the material layer forming unit U2 moves to the laminating unit U3 side. As a result, the intermediate carrier 111 and the third intermediate carrier 30 come into contact with each other to form a secondary transfer portion.

(Preheater heater)
The preheating heater 31 is installed to preheat the material layer M that is electrically supported and conveyed by the third intermediate carrier 30 so as to approach the softening temperature of the material layer M. As shown in FIG. 6, by heating the material layer M on the third intermediate carrier 30 to a temperature lower than the softening temperature of the material layer M, the material layer M on the third intermediate carrier 30 is intermediately shaped. After the transfer to S, the heating time for heating the material layer M by the heater 22 can be shortened.
The elastic roller 33 is arranged so as to face the stage 23 located at the stacking position N via the third intermediate carrier 30. As shown in FIG. 6, by sandwiching the material layer M carried by the third intermediate carrier 30 and conveyed to the stacking position N together with the third intermediate carrier 30 between the elastic roller 33 and the intermediate modeled object S, 3 The material layer M on the intermediate carrier 30 is transferred to the intermediate shaped article S.

A high voltage power supply 38 is connected to the elastic roller 33 as a voltage applying means, and is configured to be able to apply a voltage to the elastic roller 33. Accordingly, when transferring the material layer M, in addition to the viscosity of the stacking surface Sa of the intermediate shaped article S, an electrostatic force can be used, and the material layer M on the third intermediate carrier 30 can be more easily and more reliably. Can be transferred to the intermediate shaped article S.
Further, the potential of the laminated surface Sa of the intermediate molded article S is measured by the surface electrometer 39 for measuring the potential of the laminated surface Sa of the intermediate molded article S before the transfer of the material layer M, and the measurement result is fed back to the high voltage power supply 38. It is desirable to do.

(Second cooling device)
The second cooling device 34 is a cooling device having the same function as the cooling device 24 of the first embodiment. In the present embodiment, the second cooling device 34 is arranged so as to apply cold air to the back surface of the surface of the third intermediate carrier 30 on which the material layer M is carried and conveyed. Therefore, when the third intermediate carrier 30 is air-cooled, the contamination adhering to the surface of the third intermediate carrier 30 and the modeling material remaining on the third intermediate carrier 30 without being transferred to the intermediate modeling object S are blown off. It is possible to cool the third intermediate carrier 30 with stronger wind force.

(Fourth cleaning device)
The fourth cleaning device 36 is means for collecting the modeling material and contaminants remaining on the third intermediate carrier 30 and cleaning the surface of the third intermediate carrier 30. The fourth cleaning device 36 of the present embodiment is installed so as to sandwich the third intermediate carrier 30 with the metal roller 35. In the present embodiment, the fourth cleaning device 36 employs a blade system in which particles of the molding material, contaminants, and the like are scraped off by a cleaning blade that is in contact with the third intermediate carrier 30 in the counter direction. It is not limited to this. For example, a brush method or an electrostatic adsorption method may be used as the cleaning method.

<Sixth Embodiment>
The sixth embodiment will be described below.
FIG. 7 is a diagram schematically showing the modeling apparatus according to the present embodiment.
In this embodiment, as shown in FIG. 7, the elastic rollers 32 and 33 are configured to be movable, and the material layer forming unit U2 is fixed to the modeling apparatus main body. Further, the preheating heater 31 is also configured to be movable, and when the elastic rollers 32 and 33 move, the preheating heater 31 moves to a position away from the third intermediate carrier 30.

When the material layer M is transferred from the intermediate carrier 111 to the third intermediate carrier 30, the elastic roller 32 moves to the roller 114 side of the material layer forming unit U2, and at the same time, the elastic roller 33 moves the same distance. As a result, the third intermediate carrier 30 takes the transfer position (the position indicated by the dotted line 30a in FIG. 6) at which the material layer M is transferred from the intermediate carrier 111, comes into contact with the intermediate carrier 111, and is the secondary transfer portion. To form. At this time, the elastic roller 33 moves toward the elastic roller 32 and the metal roller 35.
When the material layer M is transferred to the third intermediate carrier 30, the elastic roller 33 moves to a position where the stacked surface Sa of the intermediate modeled object S and the third intermediate carrier 30 can contact each other. Simultaneously with the movement of the elastic roller 33, the elastic roller 32 moves toward the elastic roller 33 and the metal roller 35 by the distance that the elastic roller 33 has moved. As a result, the third intermediate carrier 30 takes a position apart from the intermediate carrier 111. While the elastic rollers 32 and 33 move, the material layer M is conveyed toward the stacking position N by the third intermediate carrier 30. However, until the movement of the elastic rollers 32 and 33 is completed, the image detection sensor 21 detects the material layer M. It is configured so as not to reach the detection area.

When the movement of the elastic rollers 32 and 33 is completed, the material layer M on the third intermediate carrier 30 passes through the detection area of the image detection sensor 21 and is transferred to the intermediate molded article S.
In the present embodiment, two of the three rollers that stretch the third intermediate carrier 30 are configured to be movable, but the present invention is not limited to this. That is, at least one of the plurality of rollers that stretches the intermediate carrier is configured to be movable, and the movement of the roller causes the intermediate carrier to separate from the material layer forming unit U2 except when the material layer M is transferred. Can take different positions. Accordingly, the material layer forming unit U2 can be configured so as not to be affected by the heat generated in the laminating unit U3.

<Seventh Embodiment>
The seventh embodiment will be described below.
FIG. 8 is a diagram schematically showing the modeling apparatus according to this embodiment.
In the present embodiment, as shown in FIG. 8, the modeling apparatus includes the heater 22, the image forming units 10a and 10b, the second heater 29, and the stage 23. In the modeling apparatus of the present embodiment, material images are sequentially transferred from the image carriers 100a and 100b to the stacking surface Sa of the intermediate modeled article S on the stage 23 without the intermediate carrier as in the above-described embodiment. , The material layer M is formed on the intermediate shaped article S.

The modeling operation of the modeling apparatus of this embodiment will be described below.
First, the stage 23 moves to a position facing the heater 22 (FIG. 8). At this position, heating by the heater 22 is performed so that the temperature of the stacking surface Sa of the intermediate shaped article S on the stage 23 becomes equal to or higher than the softening temperature of the intermediate shaped article S.
When the stacking surface Sa of the intermediate modeling object S is heated to the softening temperature of the intermediate modeling object S or higher, the stage 23 is moved to the facing portion of the image carrier 100a, and the material image made of the modeling material Ma shows the intermediate modeling object S. Transcribed on.

When the material image made of the molding material Ma is transferred, the stage 23 is moved to the facing portion of the image carrier 100b, and the material image made of the molding material Mb is transferred onto the intermediate molded article S.
In this way, the material layer M is formed on the intermediate modeling object S by transferring the material image composed of the modeling materials Ma and Mb. After that, the stage 23 moves to the facing portion of the second heater 29, and the material layer M is sandwiched between the second heater 29 and the intermediate modeling object S, so that the material layer M is heated and/or pressurized to be intermediate. It is fixed on the molded article S.
Here, since the image carriers 100a and 100b come into contact with the heated intermediate modeling object S via the material image, there is a concern that the heat of the intermediate modeling object S is transmitted and the temperature rises. Therefore, it is desirable to install cooling devices 106a and 106b for cooling the image carriers 100a and 100b. The cooling device 106 is arranged downstream of the stacking position where the image carrier 100 comes into contact with the intermediate modeling object S via the material image in the rotational direction of the image carrier 100 and upstream of the cleaning device 105. Good. Further, the image carrier 100 may have only one structure, and after the material image is formed on one image carrier 100, the material image is transferred to form the material layer on the intermediate modeling object S. You may.

<Eighth Embodiment>
The eighth embodiment will be described below.
9A to 9D are diagrams schematically showing the modeling apparatus according to the present embodiment.
FIG. 9A shows the overall configuration of the modeling apparatus. As shown in FIG. 9A, the modeling apparatus of this embodiment includes the image forming unit 10, the fourth intermediate carrier 40, the transfer assisting member 41, the third heater 46, and the stage 23. 9B to 9D are diagrams for explaining the positional relationship among the fourth intermediate carrier 40, the transfer assisting member 41, the third heater 46, and the stage 23. The configuration unique to this embodiment will be described in detail below.

(Fourth intermediate carrier)
On the fourth intermediate carrier 40, the material images formed by the image forming units 10 are transferred, and the material layer M is formed. That is, after the material image of the modeling material Ma is transferred from the image forming unit 10 a on the upstream side, and the material image of the modeling material Mb is transferred from the image forming unit 10 b on the downstream side, the fourth intermediate carrier 40 is transferred. One material layer M is formed on the substrate.
The fourth intermediate carrier 40 is an endless belt member made of a material such as resin or polyimide, and is stretched around a plurality of rollers 42, 43, 44 as shown in FIG. 9A. A tension roller may be provided in addition to the rollers 42, 43, and 44 so that the tension of the fourth intermediate carrier 40 can be adjusted. At least one of the rollers 42, 43, and 44 is a driving roller, and the fourth intermediate carrier 40 is rotated counterclockwise in the figure by the driving force of a motor (not shown) when forming the material layer.

(Transfer auxiliary member)
The transfer assisting member 41 is composed of a flat plate made of a metal such as SUS or aluminum, and is installed so as to face the stage 23 with the fourth intermediate carrier 40 interposed therebetween, as shown in FIGS. 9A and 9B.
The material layer M conveyed to the stacking position N facing the intermediate shaped article S by the fourth intermediate carrier 40 is sandwiched between the transfer assisting member 41 and the intermediate shaped article S, so that the material is transferred onto the intermediate shaped article S. Transferred and laminated. When the material layer M is transferred, the fourth intermediate carrier 40 and the rollers 42, 43, 44 are stopped. A heater may be built in the transfer assisting member 41, and the temperature of the heater is set to be equal to or lower than the softening temperature of the material layer M. It is desirable that an elastic member such as urethane or silicone is attached to the surface of the transfer assisting member 41 on the side of the fourth intermediate carrier 40, so that the material layer M and the fourth intermediate carrier 40 come into contact with each other. Easier to do.

(heater)
The third heater 46 is a temperature control unit that controls the temperatures of the intermediate molded article S and the material layer M transferred and laminated on the intermediate molded article S. The third heater 46 has a first position shown in FIG. 9D, which is a position sandwiched between the fourth intermediate carrier 40 and the stage 23, and a second position shown in FIGS. 9B and 9C, which is separated from the first position. It is installed so that it can move between. In FIG. 9D, the third heater 46 located at the first position is indicated by 46a, and in FIGS. 9B and 9C, the third heater 46 located at the second position is indicated by 46b. In addition, in the present embodiment, the third heater 46 is configured to be movable on the belt surface of the fourth intermediate carrier 40 at the stacking position N in a direction orthogonal to the transport direction of the fourth intermediate carrier 40.

  When the material layers M are stacked, the intermediate shaped article S is heated by the third heater 46 located at the first position shown in FIG. 9D, and thereafter, until the material layer M reaches the stacking position N. , The third heater 46 is moved to the second position shown in FIGS. 9B and 9C. Then, when the material layer M is transferred to the intermediate modeling object S, the third heater 46 is again positioned at the first position shown in FIG. 9D. Then, after the material layer M is transferred to the intermediate modeling object S, the intermediate modeling object S to which the material layer M is transferred and the third heater 46 are brought close to each other, so that the part of the material layer M transferred to the intermediate modeling object S. Is melted and fixed to the intermediate molded article S. As the third heater 46, for example, a ceramic heater or a halogen heater can be used. The temperature of the third heater 46 is preferably set to be equal to or higher than the temperature at which the material layer M is melted. By adjusting the distance between the third heater 46 and the intermediate modeled article S, the laminated surface Sa of the intermediate modeled article S is adjusted. The temperature of can be controlled.

(stage)
In the present embodiment, the stage 23 is configured to be movable only in the stacking direction of the material layers M (direction perpendicular to the belt surface of the fourth intermediate carrier 40 at the stacking position N) by a driving unit such as an actuator (not shown). Has been done.
The stage 23 is lowered (in a direction away from the stacking position N) in a state before the material layers M are stacked, and is moved upward when the material layers M are stacked. The position of the stage 23 at this time is set by adjusting the distance between the stage 23 and the third heater 46 based on the temperature of the stacking surface Sa of the intermediate modeling object S. Then, heating by the third heater 46 is performed until the temperature of the laminated surface Sa of the intermediate shaped article S on the stage 23 becomes equal to or higher than the softening temperature of the intermediate shaped article S. When the material layer M is conveyed to the stacking position N, the stage 23 moves up, and the material layer M is sandwiched between the stage 23 and the transfer assisting member 41, so that the material layer M is transferred to the intermediate modeling object S. When the material layer M is transferred to the intermediate modeling object S, the stage 23 moves downward, and then the third heater 46 moves to the first position shown in FIG. 9D, whereby the material layer M is moved by the third heater 46. Is melted and fixed to the intermediate molded article S.

  The embodiments described above are intended to exemplify the embodiments of the present invention, and may be combined and variously modified as much as possible without departing from the scope of the present invention. Is.

  DESCRIPTION OF SYMBOLS 1... Modeling apparatus, 20... Second intermediate carrier, 22... Heater, 23... Stage, Ma, Mb... Modeling material, S... Intermediate modeled article

Claims (19)

In a modeling apparatus for manufacturing a three-dimensional three-dimensional object by stacking thermoplastic modeling materials carried on a carrier on a stage,
Heating means for heating the laminated surface of the three-dimensional object on the stage,
On the laminating surface of the three-dimensional object on the stage, laminating means for laminating the modeling material carried on the carrier,
Control means for controlling the heating means and the laminating means,
Has
The control means controls the heating means to heat the lamination surface to a softening temperature of the molding material or higher, and to control the lamination surface to stack the molding material at a temperature lower than the softening temperature. Modeling equipment. As for the softening temperature, the temperature dependence of the storage elastic modulus and the loss elastic modulus in the shear direction of the molded body obtained by pressure molding the aggregate of the molding material into a cylindrical shape having a diameter of 10 mm and a thickness of 1 mm is set to an angular frequency of 1 Hz. The modeling apparatus according to claim 1, wherein the storage elastic modulus is a temperature at which the storage elastic modulus is 10 MPa when the temperature is measured at a rate of 2° C./minute by the rotary rheometer. The modeling apparatus according to claim 1, wherein the heating unit holds an ambient temperature around a three-dimensional object on the stage at a target temperature in order to heat the three-dimensional object on the stage. The stage and/or the heating means are movably arranged between a position when the lamination is performed by the lamination means and a position when the three-dimensional object on the stage is heated by the heating means. The modeling apparatus according to claim 1 or 2, wherein the modeling apparatus is provided. After the modeling material is laminated on the laminated surface of the three-dimensional object on the stage, the function of pressing the three-dimensional object on the stage on which the modeling material is laminated and/or the heating of the laminated modeling material The modeling apparatus according to claim 1, further comprising a member having a function.   On the surface of the stage on which the modeling material is laminated, a layer formed of a material soluble in a solvent, or a temperature-sensitive adhesive that changes in stickiness and non-stickiness according to temperature change is provided in advance. The modeling apparatus according to any one of claims 1 to 5, further comprising: The solvent-soluble material is a thermoplastic material,
When the modeling material is directly laminated on the thermoplastic material layer, the control means heats the thermoplastic material layer by the heating means to a temperature equal to or higher than the softening temperature of the thermoplastic material. The modeling apparatus according to claim 6. A material layer forming means for forming a material layer made of the modeling material based on the slice data of the three-dimensional model,
8. The carrier according to claim 1, wherein the carrier is a carrier that conveys the material layer formed by the material layer forming means to a stacking position where the stacking is performed by the stacking means. The modeling apparatus according to any one of claims. 9. The preheating means for heating the material layer so that the temperature of the material layer carried by the carrier and conveyed toward the stacking position approaches the softening temperature. Modeling equipment. 9. A cleaning unit, which is arranged downstream of the stacking position in the carrying direction of the material layer by the carrier, and which cleans a carrying surface of the carrier carrying the material layer. Or the modeling apparatus according to 9. 11. The cooling unit, which is arranged downstream of the stacking position in the transport direction of the material layer by the carrier, and cools the carrier, is described in any one of claims 8 to 10. Modeling equipment. The carrier electrically carries the material layer,
A voltage applying means for applying a voltage to the carrier,
The laminating means applies a voltage to the carrier by the voltage applying means when laminating the material layer on the carrier on the laminating surface of the three-dimensional object on the stage. The modeling apparatus according to any one of 8 to 11. The modeling apparatus according to claim 8, wherein the carrier is a belt member made of resin or metal. A plurality of rollers for stretching the carrier,
The carrier is located at a transfer position where the material layer is transferred from the material layer forming unit to the carrier or at a position distant from the material layer forming unit with respect to the transfer position. 14. The modeling apparatus according to claim 13, wherein at least one of the rollers is movably arranged. The modeling apparatus according to claim 8, wherein the carrier is a tubular member made of resin or metal. An image forming unit that forms an image made of the modeling material based on the slice data of the three-dimensional model,
The modeling apparatus according to any one of claims 1 to 7, wherein the carrier is a member on which an image of the modeling material is formed in the image forming unit. A plurality of the image forming units are provided,
The image of the modeling material formed in each image forming unit based on the slice data for one layer is sequentially stacked on the stacking surface of the three-dimensional object on the stage. Modeling equipment. After the image of the modeling material carried on the carrier is stacked on the stacking surface of the three-dimensional object on the stage, cooling is performed to cool the region of the carrier on which the image of the modeling material was carried. The modeling apparatus according to claim 16 or 17, further comprising means. A modeling method using a modeling apparatus for manufacturing a three-dimensional three-dimensional object by stacking a thermoplastic modeling material carried on a carrier on a stage, the method comprising:
A heating step of heating the laminated surface of the three-dimensional object on the stage,
Lamination for laminating the modeling material, which is carried by the carrier and is lower than the softening temperature, on the laminating surface of the three-dimensional object on the stage heated to the softening temperature of the modeling material or higher by the heating step. Process,
A molding method comprising:

Images