JP6944849B2 - Manufacturing method of three-dimensional model and support material composition for three-dimensional model - Google Patents

Description

The present invention relates to a method for manufacturing a three-dimensional model and a support material for three-dimensional modeling.

The three-dimensional model is manufactured by an additional manufacturing device generally called a 3D printer. The additional manufacturing equipment extrudes or coats a molding material such as a thermoplastic resin, a photocurable resin, a powder resin, or a powder metal into a predetermined area by melt extrusion or inkjet, and then fuses using a laser beam, an electron beam, or the like. By curing, the modeling materials are stacked in a thin film to produce the desired three-dimensional model. With this method, a modeled object can be obtained directly from the shape data, and complex shapes such as hollow and mesh can be integrally molded. Therefore, small lot or custom-made test models can be created, medical, aircraft industry, industrial robots, etc. The fields of use are expanding.

Specifically, as the additional manufacturing equipment, an inkjet ultraviolet curing method using a photocurable resin such as acrylic, a fused deposition modeling method using a thermoplastic resin such as acrylonitrile, butadiene, and styrene resin, and other powder molding methods and light A modeling method 3D printer is known.

Although it is possible to form a three-dimensional model with a complicated shape by additional manufacturing technology, when manufacturing a hollow structure, in order to prevent the three-dimensional model from being deformed by its own weight, the three-dimensional model is supported and the shape is maintained. Supports for this may be used. For example, in the case of a powder molding method in which powder molding materials are bound or fused, unbonded and unfused powder molding materials act as supports, and these are wiped off after molding. A three-dimensional model can be obtained. On the other hand, in the inkjet method in which the photocurable resin is gradually cured and the fused deposition modeling method in which the thermoplastic resin is melt-extruded and laminated, the three-dimensional model material (modeling material) and the support material are used. It is necessary to remove the support material from the three-dimensional model after molding in order to form the support.

Since the support material is fused, adhered or adhered to the three-dimensional model, when removing the support material from the three-dimensional model, it can be manually peeled off with a spatula or brush, or blown off with a water jet. However, careful work is required because there is a risk of damage to the three-dimensional model. In addition, thermoplastic resin, heat-meltable wax, material that can be dissolved in water or organic solvent, water-swelling gel, etc. are used as the support material, and heating, melting, chemical reaction, hydraulic cleaning, etc. are performed according to the properties of the support material. Separation methods using power cleaning, electromagnetic wave irradiation, thermal expansion difference, etc. have also been proposed.

Japanese Unexamined Patent Publication No. 2005-35299 Japanese Unexamined Patent Publication No. 2016-537034

However, when trying to dissolve and remove the support material with water, the support material must have the physical properties of being easily soluble in water and immediately soluble because the dissolving ability of water is lower than that of alkali or solvent. It is difficult to select the material of the support material that has physical characteristics. When trying to melt and remove the support material by heating, depending on the melting point of the support material, even the model material may melt, making it difficult to select the material for the support material and setting the conditions for removing the support material. Is. Attempts have also been made to use electromagnetic wave irradiation and thermal expansion difference as a method for removing the support, but the current situation is that they are still under development and have not been put into practical use. Therefore, there is a demand for a support material that can be easily removed without damaging the three-dimensional model.

The present invention has been made to solve the above-mentioned problems, and provides a method for manufacturing a three-dimensional model and a support material composition for three-dimensional modeling, which can easily remove the support material after forming the three-dimensional model. The purpose is to do.

The method for manufacturing a three-dimensional model of the present invention includes a step of applying a modeling material on a base material and forming a modeling material layer based on cross-sectional information of the three-dimensional model, and applying a support material composition on the base material. A method for producing a three-dimensional model, which comprises a step of forming a support material layer that supports the modeling material layer, wherein the support material composition contains ethylene carbonate.

It is preferable that the method for producing a three-dimensional model of the present invention further includes a step of bringing the three-dimensional model precursor composed of the modeling material layer and the support material layer into contact with water to remove the support material layer. In this case, the temperature of water in the step of removing the support material layer is preferably 40 ° C. or higher.

It is preferable that the method for producing a three-dimensional model of the present invention further includes a step of heating the three-dimensional model precursor composed of the modeling material layer and the support material layer to remove the support material layer. In this case, the heating temperature in the step of removing the support material layer is preferably 38 ° C. or higher.

The three-dimensional modeling support material composition of the present invention is characterized by containing ethylene carbonate.

In the present specification, the reference numeral of "~" in the description of "lower limit value to upper limit value" means that the range is equal to or more than the lower limit value and less than or equal to the upper limit value.

According to the method for producing a three-dimensional model and the support material composition for three-dimensional modeling of the present invention, the support material after forming the three-dimensional model can be easily removed.

It is a figure for demonstrating the manufacturing method of the three-dimensional object of this invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a diagram for explaining a method for manufacturing a three-dimensional model of the present invention. The method for producing a three-dimensional model of the present invention includes a step (A) of applying a modeling material on a base material 2 and forming a modeling material layer 10 based on cross-sectional information of the three-dimensional model, and a support material composition. This is a method of manufacturing a three-dimensional model by applying it on the base material 2 and performing the step (B) of forming the support material layer 30 that supports the modeling material layer 10. The support material composition used in the method for producing a three-dimensional model of the present invention is characterized by containing ethylene carbonate (ethylene carbonate) represented by the following formula (1).

In the step (A) of forming the modeling material layer 10, a modeling material to be a material of the three-dimensional modeling object is applied based on the cross-sectional information of the three-dimensional modeling object. Since the modeling material is usually solid at room temperature, it is preferable to heat the modeling material to melt it and apply it in a liquid state.

The cross-sectional information of the three-dimensional model can be created by creating cross-sectional data corresponding to the three-dimensional shape of the desired three-dimensional object in an arbitrary format according to the device to be used. As a method of generating cross-sectional information of a three-dimensional model, for example, three-dimensional CAD (computer-aided design) data of an object to be modeled is used, and the above CAD data is used as data for three-dimensional modeling, for example, three-dimensional STL (Stereo). Each of the three-dimensional STL data is converted into Lithografy data and sliced in any one direction (for example, in the height direction) at a pitch (layer thickness) corresponding to the thickness of one layer of the CAD material layer 10. A method of generating cross-sectional body (layer) data can be mentioned. The pitch can be appropriately determined according to the modeling material to be used, the desired accuracy, and the like. Further, the data of each cross-sectional body (layer) may have color information (coloring data) of each part, if necessary. Furthermore, it is also possible to use the data and texture of the three-dimensional colored shape measured by the three-dimensional shape input device.

In the present invention using the support material composition, the "cross-sectional information of the three-dimensional modeled object" includes not only the cross-sectional information of the three-dimensional modeled object itself but also the cross-sectional information of the support material provided when forming the three-dimensional modeled object. included.

As a method of applying the modeling material in the step (A) of forming the modeling material layer 10, a method using an inkjet method in which a modeling material liquid liquefied by heating and melting is discharged by an inkjet head 4 is conventionally known. It is preferable because it can be applied to the device. In the inkjet method, the inkjet head 4 can move on the XY plane based on the cross-sectional information of the three-dimensional model to form the modeling material layer 10 having a predetermined thickness.

As described above, the thickness of the modeling material layer 10 in the step (A) of forming the modeling material layer 10 is determined according to the modeling material used, the desired accuracy, and the like. The thickness of the modeling material layer 10 is preferably 0.1 to 200 μm, more preferably 1 to 150 μm, and 10 to 100 μm from the viewpoint of modeling accuracy, strength of the modeling material layer 10, manufacturing efficiency, and the like. Is more preferable. Further, the resolution of ejection of the modeling material by the inkjet head 4 in the step (A) of forming the modeling material layer 10 is appropriately selected according to the accuracy of the desired three-dimensional model and the accuracy of the cross-sectional information of the three-dimensional model. be able to.

When the inkjet method is used, a general photocurable ink that can be used in the inkjet modeling method can be used as the modeling material for forming the modeling material layer 10. Examples of such photocurable inks include Stratasys'VeroWhitePlus, VeroBlackPlus, VeroBlue, VeroGray, VeroClear, etc., Keyence's AR-M1, AR-M2, and Mimaki Engineering's LH100Clear Liquid, LH100. LH100Magenta, LH100White, LH100Black, LF-140Cyan, LF-140LightCyan, LF-140Yello, LF-140Magenta, LF-140Light Magenta, LF-140White, LF-140White, LF-140Black, etc. These photocurable inks may be used alone or in combination of two or more. Further, in order to form a color three-dimensional model, it is preferable to use two or more kinds of color photocurable inks containing a coloring pigment in the modeling material.

The method for producing a three-dimensional model of the present invention preferably includes a curing step of photocuring the modeling material layer 10. Examples of the light that can be used in the curing step include ultraviolet light, visible light, and infrared light. The peak wavelength of light depends on the absorption characteristics of the photopolymerization initiator and the sensitizer contained in the photocurable ink, but is preferably 200 to 600 nm, more preferably 300 to 450 nm, for example. , 320 to 420 nm, and particularly preferably ultraviolet light having a peak wavelength in the range of 340 to 400 nm.

In the step (B) of forming the support material layer 30, the support material composition containing ethylene carbonate is applied onto the base material 2 to form the support material layer 30. The support material composition functions as a support material for supporting the modeling material layer 10 by being applied around the position where the modeling material is applied, if necessary.

The support material layer 30 can be formed in any shape. For example, the support material layer 30 may be formed so that the minimum necessary support material is formed when forming the three-dimensional model, or sufficient support material is provided around or inside the three-dimensional model. The support material layer 30 may be formed so as to be formed.

As a method of applying the support material composition in the step (B) of forming the support material layer 30, a method using an inkjet method in which the support material composition liquefied by heating and melting is ejected by the inkjet head 4 is used. It is preferable because it can be applied to a conventionally known device. The heating temperature at this time is preferably the melting point of ethylene carbonate, that is, 38 ° C. or higher. At this time, a plurality of inkjet heads 4 may be used so as to apply the modeling material and the support material composition separately, or the modeling material and the support material composition may be applied by the common inkjet head 4.

As described above, the thickness of the support material layer 30 in the step (B) of forming the support material layer 30 is determined according to the modeling material used, the desired accuracy, and the like. The thickness of the support material layer 30 is preferably 0.1 to 200 μm, more preferably 1 to 150 μm, and further preferably 10 to 100 μm from the viewpoint of the strength of the support material, manufacturing efficiency, and the like. preferable. Further, the resolution of ejection of the support material composition by the inkjet head in the step (B) of forming the support material layer 30 is appropriately selected according to the accuracy of the desired three-dimensional model and the accuracy of the cross-sectional information of the three-dimensional model. can do.

The support material composition contains ethylene carbonate, preferably ethylene carbonate as a main component. Ethylene carbonate has a relatively low melting point of 38 ° C. and has sufficient strength even in a solid state. It is also resistant to impact. Therefore, sufficient support is possible. In addition, it is water-soluble and has a low viscosity (1.9 mPa · s at 40 ° C.), and is extremely easily removed by water. Therefore, it is not necessary to contact with water for a long time, and precise removal is possible in every detail. The main component here means 50% by mass or more of the entire composition. The content ratio of ethylene carbonate is more preferably 80% by mass or more, further preferably 90% by mass or more, and particularly preferably 95% by mass or more, based on the total amount of the support material composition.

Further, ethylene carbonate and a known water-soluble support material may be mixed and used as a support material composition. Thereby, the washing performance of the support material can be improved. When ethylene carbonate and a known water-soluble support material are mixed, the content of ethylene carbonate is preferably 2 to 30% by mass, more preferably 5 to 20% by mass, based on the total amount of the support material composition.

The support material composition may contain other components in addition to ethylene carbonate, if necessary. Examples of other components include thickeners and antibacterial agents. As the thickener, hydrophilic synthetic polymer resins such as carboxyvinyl polymer, carboxymethyl cellulose, carboxyethyl cellulose, and methyl cellulose can be used, and as the antibacterial agent, phenoxyethanol, salicylic acid, paraben, 1,2hexanediol and the like can be used.

The step (A) for forming the modeling material layer 10 and the step (B) for forming the support material layer 30 in the method for producing a three-dimensional model of the present invention may be performed at the same time or in order. If they are performed in order, either of them may be performed first. Further, the number of steps (A) for forming the modeling material layer 10 and the step (B) for forming the support material layer 30 in the method for manufacturing a three-dimensional model of the present invention may be only once, or may be performed a plurality of times. May be good. The number of these steps can be appropriately set depending on the shape of the three-dimensional model, the type of modeling material, and the like. When the step (A) for forming the modeling material layer 10 and the step (B) for forming the support material layer 30 are performed a plurality of times, these are alternately performed or the step (A) for forming the modeling material layer 10 is performed. It is preferable to perform the step (B) for forming the support material layer 30 at the same time a plurality of times.

In the method for producing a three-dimensional model of the present invention, in the first step (A) of forming the modeling material layer 10, the base material 2 is prepared, for example, as a base of a three-dimensional modeling device to be used, a modeling table, or separately. Any substrate, support or article made of. Further, the support material layer 30 may be formed of one layer or a plurality of layers to serve as the base material 2. In the second and subsequent steps (A) of forming the modeling material layer 10, the base material 2 is composed of the already formed modeling material layer 10, the support material layer 30, or the modeling material layer 10 and the support material layer 30. It is a three-dimensional model precursor.

Since the melting point of ethylene carbonate in the support material composition forming the support material layer 30 as described above is 38 ° C., the base material 2 is maintained at a temperature of less than 38 ° C. Examples of the method of keeping the base material 2 below 38 ° C. include a method of cooling the base material 2, a method of installing a cooling means on the lower surface of the base material 2, a method of installing the apparatus itself in a low temperature box, and the like. Can be used.

It is preferable that the manufacturing method of the present invention further includes a step of removing the support material layer 30 by bringing the three-dimensional modeled product precursor formed by laminating the modeling material layer 10 and the support material layer 30 into contact with water. .. As described above, since ethylene carbonate is water-soluble, the support material layer 30 can be easily removed by bringing the three-dimensional model precursor into contact with water.

As a method of bringing the three-dimensional model precursor into contact with water, for example, a method of immersing the three-dimensional model precursor in water, a method of pouring water over the three-dimensional model precursor, and the like can be used. As a method of pouring water on the three-dimensional model precursor, for example, a method of showering water on the three-dimensional model precursor may be used. Due to its low viscosity, ethylene carbonate can be removed very easily with water, allowing precise removal in every detail.

In the method of bringing the three-dimensional model precursor into contact with water, the temperature of water is preferably 40 ° C. or higher. Since ethylene carbonate has a relatively low melting point of 38 ° C., the support material layer 30 becomes liquid when brought into contact with water at 38 ° C. or higher. In order to precisely remove the support material layer from the three-dimensional structure precursor, the temperature of water is preferably 40 ° C. or higher in consideration of the specific heat of water and the support material. As a result, the support material layer 30 can be removed extremely quickly.

Further, since ethylene carbonate has a melting point of 38 ° C., the three-dimensional model precursor may be heated to 38 ° C. or higher when removing the support material layer 30. As a result, the support material layer 30 can be easily removed, and since the liquid ethylene carbonate has a low viscosity, precise removal is possible in every detail.

As described above, according to the method for producing a three-dimensional model of the present invention, since the support material composition contains ethylene carbonate as a main component, it is extremely easy to remove the support material from the precursor of the three-dimensional structure, and it is simple. Precise removal is possible in every detail by the method.

Claims (9)

The process of applying the modeling material on the base material and forming the modeling material layer based on the cross-sectional information of the three-dimensional model,
A method for producing a three-dimensional model, which comprises applying a support material composition onto the base material and forming a support material layer that supports the model material layer.
The support material composition is a method for producing a three-dimensional model, which comprises ethylene carbonate represented by the following formula (1).

The three-dimensional model precursor consisting of the model material layer and the support material layer is brought into contact with water.
The method for manufacturing a three-dimensional model according to claim 1, further comprising a step of removing the support material layer. The method for producing a three-dimensional model according to claim 2, wherein the temperature of water in the step of removing the support material layer is 40 ° C. or higher. By heating the three-dimensional model precursor composed of the model material layer and the support material layer,
The method for manufacturing a three-dimensional model according to claim 1, further comprising a step of removing the support material layer. The method for producing a three-dimensional model according to claim 4, wherein the heating temperature in the step of removing the support material layer is 38 ° C. or higher. The method for producing a three-dimensional model according to any one of claims 1 to 5, wherein the melting point of ethylene carbonate is 38 ° C. The method for producing a three-dimensional model according to any one of claims 1 to 6, wherein the temperature of the base material is maintained below 38 ° C. A support material composition for three-dimensional modeling containing ethylene carbonate represented by the following formula (1).

The support material composition for three-dimensional modeling according to claim 8, wherein the melting point of ethylene carbonate is 38 ° C.

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