WO2015072134A1

WO2015072134A1 - Manufacturing method of three-dimensional structure and three-dimensional structure

Info

Publication number: WO2015072134A1
Application number: PCT/JP2014/005667
Authority: WO
Inventors: Eiji Okamoto
Original assignee: Seiko Epson Corporation
Priority date: 2013-11-12
Filing date: 2014-11-11
Publication date: 2015-05-21
Also published as: TW201524748A; JP6413226B2; JP2015093433A

Abstract

The present invention relates to a manufacturing method of a three-dimensional structure (1) for manufacturing the three-dimensional structure (1) obtained by laminating a unit layer which is formed by applying an ink including a curable resin and by curing the ink. The three-dimensional structure (1) includes an outer circumferential portion (42), and a transparent covering layer (5) for covering the outer circumferential portion (42), and at the time of forming the unit layer, an outer circumferential portion forming ink is applied onto a first region corresponding to the outer circumferential portion (42), a covering layer forming ink is applied onto a second region corresponding to the covering layer, and the outer circumferential portion forming ink and the covering layer forming ink are cured.

Description

MANUFACTURING METHOD OF THREE-DIMENSIONAL STRUCTURE AND THREE-DIMENSIONAL STRUCTURE

The present invention relates to a manufacturing method of a three-dimensional structure and a three-dimensional structure.

From the related art, for example, a method for forming a three-dimensional object on the basis of a three-dimensional object model created by three-dimensional CAD software or the like is known.

As one of the methods for forming the three-dimensional object, a laminating method is known. In the laminating method, generally, the three-dimensional object model is divided into a plurality of two-dimensional cross-sectional layers, and then a cross-sectional member corresponding to each of the two-dimensional cross-sectional layers is sequentially formed, and the three-dimensional object is formed by sequentially laminating the cross-sectional members.

When there is the model of the three-dimensional object to be formed, the laminating method is able to directly form the three-dimensional object, and there is no need to prepare a mold before forming the three-dimensional object, and thus it is possible to rapidly and inexpensively form the three-dimensional object. In addition, the three-dimensional object is formed by laminating the thin plate-like cross-sectional members one by one, and thus, for example, even when the object is a complicated object including an internal structure, it is possible to form the three-dimensional object as an integrated structure without being divided into a plurality of components.

As one of such laminating methods, a technology as disclosed in PTL 1 which forms each of the cross-sectional members by using a powder material and a binder material is known. However, generally, the cross-sectional member formed by using the powder material tends to be brittle, and to be easily damaged.

Therefore, in order to solve the problem, for example, an attempt to dispose a protective layer on an outer surface of the three-dimensional object by dipping or the like after forming the three-dimensional object has been performed.

In Fig. 15, a sectional view of the three-dimensional object including the protective layer formed by dipping is illustrated. When a protective layer 65 is disposed on a outer surface with concavities and convexities 61 of the three-dimensional object 60 by the dipping, dipping liquid easily accumulates in a concave portion 62, and as illustrated in Fig. 15, a film thickness b2 of the protective layer 65 in the concave portion 62 may be thicker than a film thickness b1 of the protective layer 65 in a convex portion 63. For this reason, it is not possible to sufficiently protect the convex portion 63, and thus the convex portion 63 may be especially easily damaged by impact, friction, or the like.

Thus, according to a surface shape of the three-dimensional object, it is difficult to dispose the protective layer having a uniform film thickness by dipping or the like, and thus it is difficult to sufficiently protect the entire three-dimensional object.

In addition, according to the method for disposing the protective layer by dipping or the like, adhesiveness between the three-dimensional object and the protective layer decreases, and thus it is not possible to sufficiently protect the three-dimensional structure.

JP-A-6-218712

An object of the invention is to provide a manufacturing method of a three-dimensional structure by which a three-dimensional structure having excellent durability with respect to impact, friction, or the like is able to be manufactured efficiently.

The object is attained by the invention described below.

According to an aspect of the invention, there is provided a manufacturing method of a three-dimensional structure for manufacturing the three-dimensional structure obtained by laminating a unit layer which is formed by applying an ink including a curable resin and by curing the ink, in which the three-dimensional structure includes an outer circumferential portion, and a transparent covering layer for covering the outer circumferential portion, and at the time of forming the unit layer, an outer circumferential portion forming ink is applied onto a first region corresponding to the outer circumferential portion, a covering layer forming ink is applied onto a second region, and the outer circumferential portion forming ink and the covering layer forming ink are cured.

Accordingly, it is possible to efficiently manufacture the three-dimensional structure having excellent durability with respect to impact, friction, or the like.

In the manufacturing method of the three-dimensional structure according to this aspect, at the time of forming the unit layer, the outer circumferential portion forming ink may be applied onto the first region, the covering layer forming ink may be applied onto the second region, and then the outer circumferential portion forming ink and the covering layer forming ink may be cured.

In the manufacturing method of the three-dimensional structure according to this aspect, at the time of forming the unit layer, the covering layer forming ink may be cured while being applied onto the second region, and then the outer circumferential portion forming ink may be cured while being applied onto the first region.

Accordingly, it is possible to increase dimensional accuracy of the three-dimensional structure.

In the manufacturing method of the three-dimensional structure according to this aspect, at the time of forming the unit layer, the outer circumferential portion forming ink may be cured while being applied onto the first region, and then the covering layer forming ink may be cured while being applied onto the second region.

In the manufacturing method of the three-dimensional structure according to this aspect, the covering layer forming ink may contain inorganic nanoparticles.

Accordingly, it is possible to further increase hardness of the covering layer, and thus it is possible to further improve impact resistance of the three-dimensional structure.

In the manufacturing method of the three-dimensional structure according to this aspect, the covering layer forming ink may contain a silicone-based surfactant.

Accordingly, it is possible to further improve friction resistance of the three-dimensional structure.

In the manufacturing method of the three-dimensional structure according to this aspect, the curable resin contained in the covering layer forming ink may be a photocurable resin.

Accordingly, it is possible to form the unit layer in a relatively short period of time, and thus it is possible to further increase productivity of the three-dimensional structure.

In the manufacturing method of the three-dimensional structure according to this aspect, the photocurable resin may be an acryl-based resin.

Accordingly, it is possible to obtain the covering layer having especially excellent transparency and higher hardness.

In the manufacturing method of the three-dimensional structure according to this aspect, the acryl-based resin may contain at least one of urethane (meth)acrylate and epoxy (meth)acrylate.

Accordingly, it is possible to obtain the covering layer which has superior transparency and has further higher hardness.

In the manufacturing method of the three-dimensional structure according to this aspect, a post-process may be performed with respect to the covering layer.

According to the manufacturing method of the three-dimensional structure of the invention, it is possible to especially improve adhesiveness between the covering layer and the outer circumferential portion. For this reason, it is possible to especially effectively prevent the covering layer from being peeled off from the outer circumferential portion, and thus it is possible to more easily perform the post-process.

In the manufacturing method of the three-dimensional structure according to this aspect, the post-process may be rough surface machining.

According to the manufacturing method of the three-dimensional structure of the invention, it is possible to especially improve adhesiveness between the covering layer and the outer circumferential portion. For this reason, it is possible to especially effectively prevent the covering layer from being peeled off from the outer circumferential portion, and thus it is possible to more easily perform the rough surface machining.

In the manufacturing method of the three-dimensional structure according to this aspect, at the time of forming the unit layer, the covering layer may be formed to be thicker by a thickness which is ablated in the post-process.

Accordingly, when a part of the covering layer is ablated, it is possible to prevent the outer circumferential portion from being unintentionally exposed.

In the manufacturing method of the three-dimensional structure according to this aspect, an average thickness of the covering layer may be greater than or equal to 10 micrometers and less than or equal to 1000 micrometers.

Accordingly, it is possible to sufficiently recognize an appearance (a shape, a color, or the like) of the outer circumferential portion, and it is possible to more reliably prevent the outer circumferential portion from being damaged by impact, friction, or the like.

In the manufacturing method of the three-dimensional structure according to this aspect, an average film thickness of the outer circumferential portion may be greater than or equal to 30 micrometers and less than or equal to 200 micrometers.

Accordingly, it is possible to obtain the three-dimensional structure having especially excellent coloring properties.

In the manufacturing method of the three-dimensional structure according to this aspect, the outer circumferential portion forming ink may contain a colorant.

Accordingly, it is possible to obtain the three-dimensional structure having especially excellent coloring properties and light resistance.

According to another aspect of the invention, there is provided a three-dimensional structure which is manufactured by the manufacturing method of the three-dimensional structure according to the aspect.

Accordingly, it is possible to provide the three-dimensional structure having excellent durability with respect to impact, friction, or the like.

Figs. 1A is a perspective view illustrating a three-dimensional structure according to a first embodiment. Fig. 1B is a diagram conceptually illustrating each unit layer for configuring the three-dimensional structure. Fig. 2 is a schematic view illustrating a three-dimensional structure manufacturing apparatus for manufacturing the three-dimensional structure. Fig. 3 is a block diagram of a control unit including the three-dimensional structure manufacturing apparatus illustrated in Fig. 2. Fig. 4 is a flowchart illustrating an entire procedure of a manufacturing method of the three-dimensional structure. Fig. 5 is a flowchart illustrating a procedure of a unit layer data creation process. Fig. 6 is a flowchart illustrating a procedure of a three-dimensional structure forming process. Fig. 7A is a diagram illustrating ink applying processing and curing processing. Fig. 7B is a diagram illustrating ink applying processing and curing processing. Fig. 7C is a diagram illustrating ink applying processing and curing processing. Fig. 7D is a diagram illustrating ink applying processing and curing processing. Fig. 8A is a diagram illustrating a planar view shape of the unit layer. Fig. 8B is a diagram illustrating a planar view shape of the unit layer. Fig. 8C is a diagram illustrating a planar view shape of the unit layer. Fig. 9 is a sectional view (an enlarged detailed view) of the three-dimensional structure. Fig. 10 is a schematic view illustrating the three-dimensional structure obtained through a post-process. Fig. 11 is an enlarged detailed view illustrating another example of the three-dimensional structure. Fig. 12 is an enlarged detailed view illustrating another example of the three-dimensional structure. Fig. 13 is a flowchart illustrating a procedure of a three-dimensional structure forming process according to a second embodiment. Fig. 14 is a flowchart illustrating a procedure of a three-dimensional structure forming process according to a third embodiment. Fig. 15 is a sectional view of a three-dimensional object including a protective layer formed by dipping.

Hereinafter, preferred embodiments of the invention will be described in detail, with reference to the attached drawings.

First Embodiment

First, a first embodiment of a three-dimensional structure and a manufacturing method thereof according to the invention will be described.

Figs. 1A and 1B are diagrams illustrating the three-dimensional structure according to the first embodiment, in which Fig. 1A is a perspective view, and Fig. 1B is a diagram conceptually illustrating each unit layer for configuring the three-dimensional structure.

Furthermore, in the following description, an upper side of Figs. 1A and 1B is described as "Upper", a lower side is described as "Lower", a right side is described as "Right", and a left side is described as "Left".

First, before describing the manufacturing method of the three-dimensional structure according to this embodiment, a three-dimensional structure 1 obtained by the manufacturing method will be described.

<Three-dimensional Structure>
The three-dimensional structure 1 illustrated in Fig. 1A is entirely in the shape of a cube, and is obtained by laminating a plurality of thin film-like unit layers 7 of which a planar view shape is a square as illustrated in Fig. 1B. The unit layer 7 is obtained from a curing ink 2 (refer to Fig. 2) including a curable resin.

Furthermore, in Fig. 1B, 10 unit layers 7 are illustrated, but the number of laminated unit layers 7 is not particularly limited, and in general, is approximately several dozen to several tens of thousands.

The three-dimensional structure 1 includes a real image portion 4 positioned on a side of a central portion, and a covering layer 5 which covers at least a part (an entire part in this embodiment) of the real image portion 4.

The real image portion 4 includes a core portion 41 positioned in a central portion thereof, and an outer circumferential portion 42 which is positioned on an outer surface 45 side of the real image portion 4, and covers an entire outer surface 44 of the core portion 41.

The core portion 41 is formed by using a core portion forming ink. The outer circumferential portion 42 is formed by using an outer circumferential portion forming ink. In addition, the covering layer 5 is formed by using a covering layer forming ink.

Furthermore, the core portion forming ink, the outer circumferential portion forming ink, and the covering layer forming ink are collectively referred to as the "ink 2" (refer to Fig. 2). In addition, the core portion forming ink and the outer circumferential portion forming ink are collectively referred to as "real image portion forming ink".

Furthermore, a component material of the ink 2, or the like will be described later in detail.

A color of the core portion 41 may be any color. That is, the color of the core portion 41 may be transparent, and may be a chromatic color such as red, blue, and yellow, an achromatic color such as white, black, and gray, and a metallic luster color such as gold, and silver. Among them, it is preferable that the color of the core portion 41 be white. Accordingly, it is possible to improve coloring properties of the entire real image portion 4.

A color of the outer circumferential portion 42 may be any color insofar as it is not transparent. That is, the color of the outer circumferential portion 42 may be any color selected from a chromatic color, an achromatic color, and a metallic luster color.

A color of the covering layer 5 is substantially transparent (colorless transparent, colored transparent, or translucent).

As described above, the color of the outer circumferential portion 42 is a color other than a transparent color, and the covering layer 5 is transparent, and thus the outer circumferential portion 42 configures a visible outline of the three-dimensional structure 1. In addition, the core portion 41 is not visible from outside due to the outer circumferential portion 42.

On the other hand, the covering layer 5 has a role as a protective layer for protecting the real image portion 4, and has a function for preventing the real image portion 4 from being damaged by friction, impact, or the like. In addition, the covering layer 5, as necessary, for example, functions as a portion for showing a texture such as a mat tone or a gloss tone of the three-dimensional structure 1.

Furthermore, chromaticness or brightness of the core portion 41 and the outer circumferential portion 42 are not particularly limited, respectively. In addition, an inside region of the core portion 41 may be entirely the same color, or may be different colors. In addition, the same applies to the outer circumferential portion 42.

In addition, an average thickness of the outer circumferential portion 42 is not particularly limited. The average thickness of the outer circumferential portion 42 is, preferably greater than or equal to 30 micrometers and less than or equal to 200 micrometers, and more preferably greater than or equal to 50 micrometers and less than or equal to 150 micrometers. When the average thickness is less than the lower limit, it is difficult to form the three-dimensional structure 1 which is relatively dark. On the other hand, when the average thickness exceeds the upper limit, the coloring properties of the outer circumferential portion 42 may deteriorate.

In addition, an average thickness of the covering layer 5 is not particularly limited. The average thickness of the covering layer 5 is, preferably greater than or equal to 10 micrometers and less than or equal to 1000 micrometers, and more preferably greater than or equal to 50 micrometers and less than or equal to 500 micrometers. Accordingly, it is possible to sufficiently recognize an appearance (a shape, a color, or the like) of the real image portion 4, and it is possible to reliably prevent the real image portion 4 from being damaged by impact, friction, or the like.

In addition, an average thickness of the core portion 41 depends on a size of the three-dimensional structure 1, and at least, the average thickness of the core portion 41 is, preferably greater than 10 micrometers, and more preferably greater than or equal to 20 micrometers. When the average thickness is less than the lower limit, the coloring properties of the outer circumferential portion 42 may deteriorate.

Hereinafter, a three-dimensional structure manufacturing system 100 provided with a three-dimensional structure manufacturing apparatus 30 for manufacturing the three-dimensional structure 1 will be described.

<Three-dimensional Structure Manufacturing System 100>
Fig. 2 is a schematic view illustrating the three-dimensional structure manufacturing apparatus for manufacturing the three-dimensional structure. Fig. 3 is a block diagram of a control unit including the three-dimensional structure manufacturing apparatus illustrated in Fig. 2.

The three-dimensional structure manufacturing system (hereinafter, simply referred to as a "three-dimensional structure forming system") 100 is an apparatus which creates a model of the unit layer 7, sequentially forms each of the unit layers 7 on the basis of the model, and forms the three-dimensional structure 1 by sequentially laminating each of the unit layers 7.

As illustrated in Fig. 2 and Fig. 3, the three-dimensional structure forming system 100 includes a computer 20 for performing creation of the model of the unit layer 7 or the like, and the three-dimensional structure manufacturing apparatus (hereinafter, simply referred to as a "three-dimensional structure forming apparatus") 30 for forming the three-dimensional structure 1.

Hereinafter, each unit configuring the three-dimensional structure forming system 100 will be described in detail.

<Three-dimensional Structure Forming Apparatus 30>
As illustrated in Fig. 2, the three-dimensional structure forming apparatus 30 includes a table (a support) 32 for holding a substrate 31, a table movement device 33, a carriage 34 provided with a head unit 341, a carriage movement device 36, a curing device 37, and a drive control unit 35. In the head unit 341, a liquid droplet discharging head 345 (refer to Fig. 3) for discharging liquid droplets of the ink (a liquid material) 2 by an ink jet method is installed.

The three-dimensional structure forming apparatus 30 is an apparatus which changes a relative position between the head unit 341 and the substrate 31, discharges the liquid droplets of the ink 2 from the liquid droplet discharging head 345 toward the substrate 31, cures the ink 2 applied onto the substrate 31 by using the curing device 37, and thus forms the unit layer 7.

Furthermore, a Y direction of Fig. 2 indicates a movement direction of the substrate 31, and an X direction indicates a direction perpendicular to the Y direction in a planar view. In addition, a direction perpendicular to an XY plane defined by the X direction and the Y direction is defined as a Z direction.

As illustrated in Fig. 2, the table movement device 33 includes a base 331 extending in the Y direction, and a pair of guide rail 332a and guide rail 332b extending in the Y direction on an upper surface 331a of the base 331. In addition, the table movement device 33 includes a table movement motor 335 (refer to Fig. 3) embedded inside thereof, and a table position detecting device 336 (refer to Fig. 3).

On the guide rail 332a and the guide rail 332b, the table 32 connected to a driving shaft of the table movement motor 335 through a transmission mechanism is arranged. When the table movement motor 335 is driven, the table 32 is reciprocated along the Y direction by the guide rail 332a and the guide rail 332b.

In addition, the table movement device 33 has a function of detecting a position of the table 32 using the table position detecting device 336.

On an upper surface 32a of the table 32, the substrate 31 including a rectangular drawing surface 31a which is configured by, for example, glass, quartz, or the like, is mounted. The table 32 may include a table heating mechanism such that a temperature of the upper surface 32a is able to be adjusted.

The carriage movement device 36 includes a supporting pole 362a and a supporting pole 362b which face each other through the base 331 in the X direction, and a guide member 361 which is supported by the supporting pole 362a and the supporting pole 362b. In addition, the carriage movement device 36 includes a carriage movement motor 365 (refer to Fig. 3) and a table position detecting device 336 (refer to Fig. 3) which are embedded inside thereof.

In the guide member 361, a guide rail 363 is arranged along a direction (the X direction) in which the guide member 361 extends. On the guide rail 363, a carriage 34 connected to a driving shaft of the carriage movement motor 365 (refer to Fig. 3) through a transmission mechanism is arranged.

The supporting pole 362a includes a guide rail 364a extending along the Z direction. In addition, the supporting pole 362b includes a guide rail 364b extending along the Z direction. On the guide rail 364a and the guide rail 364b, a guide member 361 connected to the driving shaft of the carriage movement motor 365 through the transmission mechanism is arranged.

When the carriage movement motor 365 is driven, the carriage 34 is reciprocated by the guide rail 363 along the X direction, or rotated about an axis in parallel with a Z axis. In addition, when the carriage movement motor 365 is driven, the carriage 34 arranged in the guide member 361 is moved up and down by the guide rail 364a and the guide rail 364b in a Z axis direction.

In addition, the carriage movement device 36 has a function of detecting a position of the carriage 34 using a carriage position detecting device 366.

The carriage 34 supports the head unit 341.

The head unit 341 includes a plurality of liquid droplet discharging heads 345 (refer to Fig. 3) for discharging the liquid droplets of the ink 2, and a containing portion (not illustrated) for containing the ink 2. In addition, the head unit 341 for discharging the ink 2, and an LED lamp (not illustrated) for radiating ultraviolet rays may be integrally disposed in the carriage 34.

In this embodiment, a so-called piezoelectric drive type liquid droplet discharging head 345 is adopted.

In addition, the containing portion (not illustrated) is connected to a tank 348 in which the ink 2 is contained through a tube 349.

In addition, in a state where the carriage 34 and the table 32 overlap each other in a planar view, a gap is maintained between the table 32 and the carriage 34.

The curing device 37 is supported by a supporting pole 371 to be movable in a Y axis direction. The curing device 37 has a function of curing the liquid droplets of the ink 2 applied onto the substrate 31. The curing device 37 is disposed on one end side in a Y direction of the base 331.

The curing device 37 is suspended downward in the Z direction from a beam portion 371a of the supporting pole 371, and is disposed in a position overlapping the base 331 in a planar view. In a state where the curing device 37 and the table 32 overlap each other in a planar view, a gap is maintained between the table 32 and the curing device 37.

The curing device 37 includes a light source 375 (refer to Fig. 3) for emitting ultraviolet light. As the light source 375, for example, a mercury lamp, a metal halide lamp, a xenon lamp, an excimer lamp, and the like are able to be adopted.

The ultraviolet light from the light source 375 is irradiated from the curing device 37 toward the base 331. For this reason, in a state where the table 32 and the curing device 37 overlap each other in a planar view, the ultraviolet light from the curing device 37 is able to reach the substrate 31 mounted on the table 32.

Furthermore, in this embodiment, the light source 375 for radiating the ultraviolet rays is disposed in the curing device 37, but for example, a device for radiating various energy rays such as X-rays or an electron beam, a heat source for emitting heat, or the like may be disposed in the curing device 37.

As illustrated in Fig. 3, the drive control unit 35 includes a motor control unit 351, a position detection control unit 353, a discharge control unit 355, and an exposure control unit 357.

The motor control unit 351 individually controls driving of the table movement motor 335 and driving of the carriage movement motor 365 on the basis of a command from a CPU 22 provided in the computer 20.

The position detection control unit 353 individually controls the table position detecting device 336 and the carriage position detecting device 366 on the basis of a command from the CPU 22.

The discharge control unit 355 controls driving of the liquid droplet discharging head 345 on the basis of a command from the CPU 22.

The exposure control unit 357 controls a light-emitting state of the light source 375 on the basis of a command from the CPU 22.

<Computer 20>
As illustrated in Fig. 2 and Fig. 3, the computer 20 includes a control unit 21 for controlling an operation of each unit of the three-dimensional structure forming apparatus 30, a reception unit 24, and an image creation unit 25.

The control unit 21 includes the Central Processing Unit (CPU) 22, and a storage unit 23.

The CPU 22 performs various arithmetic processing as a processor in order to execute a control program 231.

The storage unit 23 includes a Read Only Memory (ROM), a Random Access Memory (RAM), or the like. In the storage unit 23, a data developing unit 232 which is a region for storing the control program 231 in which a control procedure of an operation of the three-dimensional structure forming apparatus 30 is described or a region for temporarily developing various data items, or the like is set. The storage unit 23 is connected to the CPU 22 through a data bus 29.

In addition, the image creation unit 25 and the reception unit 24 are connected to the control unit 21 through the data bus 29. In addition, the drive control unit 35 of the three-dimensional structure forming apparatus 30 is connected to the control unit 21 through an input and output interface 28 and the data bus 29.

The image creation unit 25 has a function of creating the model of the three-dimensional structure 1, or the like. The image creation unit 25 includes software for creating a three-dimensional object such as three-dimensional computer-aided design (CAD), or the like.

The image creation unit 25 has a function of creating a three-dimensional structure model 1x (refer to Fig. 5) with which the model of the three-dimensional structure 1 is created, a function of showing an outer surface 15x (refer to Fig. 5) of the three-dimensional structure model 1x such as in a Standard Triangulated Language (STL) or the like by a two-dimensional model in the shape of a polygon such as a triangle or a quadrangle, or the like.

In addition, the image creation unit 25 also has a function of creating a unit layer model 7x (refer to Fig. 5) by cutting the three-dimensional structure model 1x in the shape of a layer.

Various data items created by the image creation unit 25 are stored in the storage unit 23. The various data items are transmitted to the drive control unit 35 of the three-dimensional structure forming apparatus 30 through the input and output interface 28 and the data bus 29. The three-dimensional structure forming apparatus 30 is driven on the basis of the various transmitted data items.

The reception unit 24, for example, includes a Universal Serial BUS (USB) port, a LAN port, or the like. The reception unit 24 has a function of receiving an image file of an original object for creating the three-dimensional structure model 1x or the like from an external device (not illustrated) such as a scanner, or the like.

In addition, as illustrated in Fig. 2, a monitor (a display device) 26 and a keyboard (an input device) 27 are connected to the computer 20. The monitor 26 and the keyboard 27 are connected to the control unit 21 through the input and output interface 28 and the data bus 29, respectively (refer to Fig. 3).

The monitor 26 includes a function of displaying the image file acquired by the reception unit 24 on an image display region 261, or the like. By including the monitor 26, an operator is able to visually understand the image file or the like.

Furthermore, the input device is not limited to the keyboard 27, but a mouse, a trackball, a touch panel, or the like may be used.

By using the three-dimensional structure forming system 100 configured as described above, it is possible to efficiently form the three-dimensional structure 1 of a desired shape. Furthermore, the three-dimensional structure forming system 100 described above is an example, and an apparatus (a system) of other configurations may be used.

Next, the manufacturing method of the three-dimensional structure according to the invention will be described.

<Manufacturing Method of Three-dimensional Structure>
Fig. 4 is a flowchart illustrating an entire procedure of the manufacturing method of the three-dimensional structure. Fig. 5 is a flowchart illustrating a procedure of a unit layer data creation process. Fig. 6 is a flowchart illustrating a procedure of a three-dimensional structure forming process. Figs. 7A to 7D are diagrams illustrating ink applying processing and curing processing. Figs. 8A to 8C are diagrams illustrating a planar view shape of the unit layer. Fig. 9 is a sectional view (an enlarged detailed view) of the three-dimensional structure. Fig. 10 is a schematic view illustrating the three-dimensional structure obtained through a post-process. Fig. 11 and Fig. 12 are enlarged detailed views illustrating another example of the three-dimensional structure.

As illustrated in Fig. 4, the manufacturing method of the three-dimensional structure 1 includes a unit layer data creation process S1, a three-dimensional structure forming process S2, and a post-process S3.

In the unit layer data creation process S1, the three-dimensional structure model (the model of the three-dimensional structure 1) 1x is created, and unit layer data is created on the basis of the three-dimensional structure model 1x (refer to Fig. 5).

In the three-dimensional structure forming process S2, on the basis of the unit layer data, the unit layers 7 are sequentially formed, and the three-dimensional structure 1 is formed by sequentially laminating the unit layers 7.

In the post-process S3, a part of an outer surface 15 of the obtained three-dimensional structure 1, that is, a part of the covering layer 5 is ablated.

Furthermore, before forming the three-dimensional structure, the operator prepares the original object of the three-dimensional structure 1, and acquires the image file of the original object, or the like. The image file, for example, may have any form such as an image file obtained by reading in the original object using a two-dimensional or a three-dimensional scanner or the like, a photograph, or a sketch.

Hereinafter, the manufacturing method of the three-dimensional structure 1 will be described in detail.

First, processing for manufacturing the three-dimensional structure 1 by an instruction from the CPU 22 according to the control program 231 stored in the storage unit 23 is started.

Next, the processing proceeds to the unit layer data creation process S1.

<Unit Layer Data Creation Process S1>
Fig. 5 is a flowchart illustrating the procedure of the unit layer data creation process S1.

In this process, first, in Step S11, the image file of the original object is received by the reception unit 24 of the computer 20 described above. The received image file is displayed on the image display region 261 of the monitor 26.

Next, in Step S12, on the basis of the received image file, a real image portion model 4x (data of a solid object) including a core portion model 41x and an outer circumferential portion model 42x is created by the image creation unit 25 (refer to (A) of Fig. 5). At this time, each color (a color phase, chromaticness, and brightness), each shape, each dimension and the like of the core portion model 41x and the outer circumferential portion model 42x are set by the image creation unit 25.

Next, in Step S13, a covering layer model 5x (the data of the solid object) which covers the real image portion model 4x is created by the image creation unit 25. Accordingly, the three-dimensional structure model 1x is created (refer to (B) of Fig. 5). At this time, each color (a color phase, chromaticness, and brightness), each shape, each dimension and the like of the covering layer model 5x are set by the image creation unit 25.

Here, in the three-dimensional structure 1 according to this embodiment, as described above, a part of the covering layer 5 is ablated in the post-process. Therefore, at the time of creating the covering layer model 5x, the covering layer model 5x is created to be thicker by a thickness of the covering layer 5 which is ablated in the post-process S3.

Next, in Step S14, an outer surface 44x of the core portion model 41x, an outer surface 45x of the outer circumferential portion model 42x, and the outer surface 15x of the covering layer model 5x are shown in a two-dimensional model by the image creation unit 25.

The two-dimensional model may be any form insofar as it is obtained by a commonly used method. In this embodiment, each of the

outer surfaces

44x, 45x, and 15x is shown in a plurality of triangular two-dimensional models according to an STL format.

Next, in Step S15, a lamination direction of the three-dimensional structure model 1x is determined by the image creation unit 25. Next, as illustrated in (C) of Fig. 5, the three-dimensional structure model 1x is horizontally divided with respect to an X-Y plane by a thickness t in the lamination direction (the Z axis direction) by the image creation unit 25. Accordingly, n unit layer models 7x of the thickness t are created.

Next, in Step S16, by the image creation unit 25, on the basis of each thickness t of the unit layer model 7x, a color of the three-dimensional structure model 1x, or the like, each unit layer data item of each of the unit layer models 7x is created. When the number of unit layer models 7x is n, n unit layer data items are created. In this Step S16, the unit layer data as information of a size, a quantity, a color, a position, and a quality of the liquid droplets of the applied ink 2 is obtained.

The entire unit layer data (1, 2, ..., n-1, and n) is temporarily stored in the storage unit 23. The entire unit layer data is referred to in the three-dimensional structure forming process S2 described later whenever necessary.

Then, the obtained unit layer data or the like is output to the drive control unit 35 of the three-dimensional structure forming apparatus 30 from an output unit (not illustrated) of the computer 20.

Through such Steps (S11 to S16), the unit layer data creation process S1 is ended.

Furthermore, in the unit layer data creation process S1 described above, all Steps (S11 to S16) may not necessarily be executed. For example, the unit layer data or the like which is prepared in advance may be read from the reception unit 24, and in this case, the unit layer data creation process S1 may be omitted.

After the unit layer data creation process S1 described above is ended, the processing proceeds to the three-dimensional structure forming process S2 (refer to Fig. 4).

<Three-dimensional Structure Forming Process S2>
Fig. 6 is a flowchart illustrating the procedure of the three-dimensional structure forming process.

As illustrated in Fig. 6, the three-dimensional structure forming process S2 includes the ink applying processing (Step S21), and the curing processing (Step S22).

Furthermore, in the following description, a region corresponding to the real image portion 4, that is, a region in which the real image portion 4 is planned to be formed is referred to as a "first region". In addition, a region corresponding to the covering layer 5, that is, a region in which the covering layer 5 is planned to be formed is referred to as a "second region". In addition, a region corresponding to the core portion 41, that is, a region in which the core portion 41 is planned to be formed is referred to as an "inside region", and a region corresponding to the outer circumferential portion 42, that is, a region in which the outer circumferential portion 42 is planned to be formed is referred to as an "outside region".

Hereinafter, each processing will be sequentially described.

First, the drive control unit 35 acquires the unit layer data through the input and output interface 28 and the data bus 29.

<Ink Applying Processing>
Next, in Step S21, the ink 2 is applied onto a target portion.

In Step S21, first, on the basis of a command from the CPU 22, the table movement device 33 and the carriage movement device 36 are driven by the motor control unit 351, and the table 32 and the carriage 34 are positioned on a discharge starting point. At this time, the table 32 and the head unit 341 are positioned in a state where the table 32 and the head unit 341 overlap each other in a planar view.

Next, an ink discharge command for starting the discharge of the ink 2 from the CPU 22 is output.

The discharge control unit 355 drives the liquid droplet discharging head 345 according to the command from the CPU 22. The liquid droplet discharging head 345 discharges the liquid droplets of the ink 2 from a nozzle (not illustrated) provided in the liquid droplet discharging head 345 toward the drawing surface 31a of the substrate 31 on the basis of the unit layer data of one layer. In addition, the motor control unit 351 controls driving of the carriage movement device 36, and starts to reciprocate the carriage 34 in the X direction. In addition, the motor control unit 351 controls driving of the table movement device 33, and starts to move the table 32 in the Y direction.

By reciprocating the carriage 34 in the X direction while moving the table 32 in the Y direction, a relative position between the head unit 341 and the table 32 is changed, and the liquid droplets of the ink 2 are discharged from the liquid droplet discharging head 345 toward the substrate 31. Accordingly, the ink 2 is applied (landed) onto the target portion. Furthermore, as necessary, the carriage 34 may be rotated about the axis in parallel with the Z axis.

Then, the unit layer data of one layer is processed, the discharge of the ink 2 corresponding to the unit layer 7 of one layer is completed, and then, on the basis of a command from the CPU 22, the discharge control unit 355 stops the driving of the liquid droplet discharging head 345. In addition, the motor control unit 351 controls the driving of the carriage movement device 36 and the table movement device 33, and stops the movement of the carriage 34 and the table 32. Accordingly, a coating layer 75 corresponding to an uncured unit layer 7 of one layer as illustrated in Fig. 7A is obtained.

In addition, in the ink applying processing (Step S21), the ink 2 is applied by an ink jet method, and thus it is possible to apply the ink 2 with high reproducibility even when an applying pattern of the ink 2 has a fine shape.

<Curing Processing>
Next, when the ink applying processing (Step S21) is ended, the process proceeds to the curing processing (Step S22) for curing the coating layer 75.

In Step S22, first, on the basis of the command from the CPU 22, the motor control unit 351 drives the table movement device 33, and moves the table 32 along the Y axis direction. At this time, the table 32 is moved such that the substrate 31 on the table 32 and the curing device 37 are in a state where the substrate 31 and the curing device 37 overlap each other in a planar view.

Next, an exposure command is output from the CPU 22.

The exposure control unit 357 supplies electric power to the light source 375 of the curing device 37 according to a command from the CPU 22. The light source 375 irradiates the coating layer 75 on the drawing surface 31a of the substrate 31 with ultraviolet rays. By radiating the ultraviolet rays, the coating layer 75 is dried and cured. When a predetermined period of irradiation time has elapsed, the exposure control unit 357 shuts off the supply of the electric power to the light source 375 on the basis of the control program 231. Accordingly, the unit layer 7 as illustrated in Fig. 7B is obtained. Furthermore, the obtained unit layer 7 may be in a completely cured state or in a half cured state.

In addition, in this embodiment, the coating layer 75 is cured by radiating the ultraviolet rays, and the unit layer 7 is formed, and for example, the unit layer 7 may be formed by radiating various energy rays such as infrared rays, X-rays, or an electron beam, or the like.

Next, as illustrated in Fig. 6, after the unit layer 7 is formed by the curing processing (Step S22), it is determined whether or not the entire unit layer data has been processed (Step S23). At this time, when it is determined that the entire unit layer data, that is, n unit layer data items in total have been processed (Step S23: Yes), the three-dimensional structure forming process S2 is ended.

On the other hand, when it is determined that all the unit layers 7 are not yet formed, and thus unit layer data remains, that is, the number of processed unit layer data items has not reached the total number n (Step S23: No), the number of unit layer data items is incremented by one, and the process returns to the ink applying processing (Step S21) described above. Then, the ink applying processing (Step S21) and the curing processing (Step S22) are repeated until it is determined that the entire unit layer data has been processed (Step S23: Yes). By repeating the ink applying processing (Step S21) and the curing processing (Step S22), the unit layers 7 corresponding to each of the unit layer data items is sequentially formed, and each of the unit layers 7 is laminated.

Here, when the unit layer 7 of a second layer is formed, the liquid droplets of the ink 2 are applied onto the unit layer 7 of a first layer in a state of being positioned with respect to the unit layer 7 of the first layer. Accordingly, as illustrated in Fig. 7C, the coating layer 75 of the second layer is formed on the unit layer 7 of the first layer. Then, as illustrated in Fig. 7D, by curing the coating layer 75 of the second layer, the unit layer 7 of the second layer is formed on the unit layer 7 of the first layer. Thus, at the time of forming the unit layer 7 of the second layer and subsequent layers (2, 3, ..., n-1, and n), the unit layer 7 (2, 3, ..., n-1, and n) is formed on the unit layer 7 which is previously formed.

In addition, at the time of forming the unit layer 7 of the second layer and the subsequent layers, in the ink applying processing (Step S21), the carriage 34 is lifted up by a thickness corresponding to the thickness t of the unit layer 7 by the carriage movement device 36 before discharging the ink. Accordingly, it is possible to align a size of the liquid droplets of the applied ink 2 for each coating layer 75, and thus it is possible to form the three-dimensional structure 1 with excellent dimensional accuracy.

Through the three-dimensional structure forming process S2 described above, it is possible to obtain the three-dimensional structure 1 including the real image portion 4 and the covering layer 5 as illustrated in Fig. 1A. In addition, in this embodiment, the covering layer 5 formed to be thicker by the thickness which is ablated in the post-process described later is obtained.

In addition, in the three-dimensional structure forming process S2, according to a type of applied ink 2, three types of unit layers 7, that is, a first unit layer 7A, a second unit layer 7B, and a third unit layer 7C are formed as illustrated in Fig. 8A to Fig. 8C.

Fig. 8A illustrates a planar view shape of the first unit layer 7A formed by using only the covering layer forming ink. At the time of forming such a first unit layer 7A, first, the covering layer forming ink is applied onto the second region, and thus the coating layer 75 is formed. Then, the coating layer 75 is cured by irradiating the coating layer 75 with the ultraviolet rays. Accordingly, the first unit layer 7A corresponding to a part 5a of the covering layer 5 as illustrated in Fig. 8A is formed. In this embodiment, at least a first layer and an n-th layer are configured as the first unit layer 7A as illustrated in Fig. 8A.

Fig. 8B illustrates a planar view shape of the second unit layer 7B formed by using the outer circumferential portion forming ink and the covering layer forming ink. At the time of forming such a second unit layer 7B, first, the outer circumferential portion forming ink is applied onto an outside region of the first region, and the covering layer forming ink is applied onto the second region, and thus the coating layer 75 is formed. Then, the coating layer 75 is cured by irradiating the coating layer 75 with the ultraviolet rays. Accordingly, the second unit layer 7B corresponding to a part 42a of the outer circumferential portion 42 and a part 5a of the covering layer 5 as illustrated in Fig. 8B is formed. In this embodiment, a layer configuring a central portion side of the three-dimensional structure 1 with one layer more than the first unit layer 7A is the second unit layer 7B as illustrated in Fig. 8B.

Fig. 8C illustrates a planar view shape of the third unit layer 7C formed by using the core portion forming ink, the outer circumferential portion forming ink, and the covering layer forming ink. At the time of forming such a third unit layer 7C, first, the core portion forming ink is applied onto an inside region of the first region, the outer circumferential portion forming ink is applied onto the outside region of the first region, and the covering layer forming ink is applied onto the second region, and thus the coating layer 75 is formed. Then, the coating layer 75 is cured by irradiating the coating layer 75 with the ultraviolet rays. Accordingly, the third unit layer 7C corresponding to a part 41a of the core portion 41, a part 42a of the outer circumferential portion 42, and a part 5a of the covering layer 5 as illustrated in Fig. 8C is formed. In this embodiment, a layer configuring the vicinity of the central portion of the three-dimensional structure 1 is the third unit layer 7C as illustrated in Fig. 8C.

In addition, in Fig. 9, a sectional view (an enlarged detailed view) of the three-dimensional structure 1 is illustrated. Specifically, Fig. 9 illustrates an enlarged view of the third unit layer 7C in a planar view. Furthermore, a two-dot chain line in Fig. 9 indicates an outer surface of a covering layer 5' which is obtained by dipping.

As illustrated in Fig. 9, a corner portion 46 and a side surface portion 47 of the real image portion 4 are protected by the covering layer 5. In addition, a film thickness a3 of the covering layer 5 in the corner portion 46 is thicker than a film thickness a4 in the side surface portion 47. By disposing such a covering layer 5, it is possible to more reliably protect the corner portion 46 which is vulnerable to impact or friction and is easily damaged compared to the side surface portion 47. Therefore, it is possible to further improve friction resistance or impact resistance of the entire three-dimensional structure 1.

Thus, according to the three-dimensional structure forming process S2 described above, it is possible to form the covering layer 5 of which the thickness is thicker than the thickness of other portions (the side surface portion 47) with respect to a portion such as the corner portion 46 which is relatively vulnerable to impact or friction. In addition, according to the three-dimensional structure forming process S2 described above, a shape of the covering layer 5 is not limited to this embodiment, but it is possible to more reliably and easily form the covering layer 5 with a desired thickness in a desired portion by adjusting a portion onto which the covering layer forming ink is applied or a quantity of the covering layer forming ink to be applied according to a design.

In contrast, the covering layer 5' obtained by dipping has a film thickness b3 in the corner portion 46 which is thinner than a film thickness b4 in the side surface portion 47. Thus, when the covering layer 5' is disposed by dipping, in general, dipping liquid is not accumulated in the corner portion 46, and thus the film thickness b3 of the covering layer 5' in the corner portion 46 tends to be thinner than the film thickness b4 of the covering layer 5 in the side surface portion 47. Then, in the obtained covering layer 5, the film thickness b3 of the covering layer 5 in the corner portion 46 is thinner than the film thickness b4 of the covering layer 5 in the side surface portion 47, and thus it is not possible to sufficiently protect the corner portion 46 from friction, impact, or the like.

In addition, according to the three-dimensional structure forming process S2 described above, the real image portion 4 and the covering layer 5 are formed substantially at the same time, and thus adhesiveness between the real image portion 4 (the core portion 41 and the outer circumferential portion 42) and the covering layer 5 is especially excellent. Therefore, it is possible to improve adhesiveness between the real image portion 4 and the covering layer 5, for example, compared to a case where the outer circumferential portion 42 is formed by dipping or the like after forming the real image portion 4. For this reason, it is particularly difficult for interfacial peeling between the real image portion 4 and the covering layer 5 to occur due to friction, impact, or the like, and thus it is possible to obtain the three-dimensional structure 1 with excellent impact resistance and friction resistance.

In addition, the three-dimensional structure 1 obtained by such a three-dimensional structure forming method has especially excellent adhesiveness between the respective unit layers 7, and thus, it is particularly difficult for interfacial peeling between the respective unit layers 7 to occur.

In addition, according to such a three-dimensional structure forming method, it is possible to form the real image portion 4 and the covering layer 5 at the same time, and thus it is possible to improve productivity of the three-dimensional structure 1.

In addition, a thickness of each obtained unit layer 7 is not particularly limited, but the thickness is, preferably greater than or equal to 30 micrometers and less than or equal to 500 micrometers, and more preferably greater than or equal to 70 micrometers and less than or equal to 150 micrometers. Accordingly, productivity of the three-dimensional structure 1 is sufficiently excellent, occurrence of unintended concavities and convexities in the three-dimensional structure 1 is more effectively prevented, and thus dimensional accuracy of the three-dimensional structure 1 is able to be especially excellent.

After the three-dimensional structure forming process S2 described above is ended, the processing proceeds to the post-process S3 (refer to Fig. 4).

<Post-Process S3>
Fig. 10 is a schematic view illustrating the three-dimensional structure obtained through the post-process. Furthermore, [X] in Fig. 10 is an enlarged view of a part of the outer surface 15.

In this process (the post-process S3), rough surface machining is performed with respect to the outer surface 15 of the taken out three-dimensional structure 1, and a part of the covering layer 5 is ablated. Accordingly, it is possible to roughen the outer surface 15 of the three-dimensional structure 1 (refer to Fig. 10).

In addition, the rough surface machining may be machining by any processing such as blast processing such as a shot blasting and a sand blasting, abrasion processing using sanding or the like, and etching processing.

In addition, as described above, in the three-dimensional structure forming process S2, the covering layer 5 is formed to be thicker by the thickness which is ablated. For this reason, in this process (the post-process S3), when a part of the covering layer 5 is ablated, it is possible to prevent the real image portion 4 from being unintentionally exposed.

In addition, as described above, the three-dimensional structure 1 obtained through the three-dimensional structure forming process S2 is formed such that the film thickness a3 of the covering layer 5 in the corner portion 46 of the real image portion 4 is thicker than the film thickness a4 of the covering layer 5 in the side surface portion 47, and thus the corner portion 46 is more reliably protected by the covering layer 5. For this reason, in this process (the post-process S3), when a part of the covering layer 5 is ablated, the corner portion 46 being unintentionally exposed is more reliably prevented.

In addition, as described above, the three-dimensional structure 1 obtained through the three-dimensional structure forming process S2 has excellent adhesiveness between the covering layer 5 and the real image portion 4, and it is particularly difficult for interfacial peeling between the real image portion 4 and the covering layer 5 to occur, and thus impact resistance and friction resistance are excellent. For this reason, in this process, even when the rough surface machining is performed with respect to the three-dimensional structure 1, it is particularly difficult for a defect such as peeling of the covering layer 5 from the real image portion 4, or occurrence of a crack in the covering layer 5 to occur. Therefore, according to the three-dimensional structure 1 obtained through the three-dimensional structure forming process S2, it is possible to especially easily and reliably ablate a part of the covering layer 5.

Furthermore, in this embodiment, in this process (the post-process S3), the rough surface machining is performed, but the processing performed in this process is not limited thereto. For example, mirror-like finishing may be performed with respect to the outer surface 15. In addition, rounding or chamfering may be performed with respect to the corner portion 46 of the three-dimensional structure 1 by machining (grinding, abrasion, cutting, or the like), chemical processing, or the like. In addition, attaching which attaches other members to the three-dimensional structure 1, or deforming which deforms the three-dimensional structure 1 by applying pressure or the like may be performed.

Through the post-process S3 described above, the processing for manufacturing the three-dimensional structure 1 is ended (refer to Fig. 4).

As described above, according to the manufacturing method of the three-dimensional structure 1 of this embodiment, it is possible to easily and reliably obtain the covering layer 5 which functions as the protective layer of the real image portion 4, and thus it is possible to obtain the three-dimensional structure 1 having especially excellent friction resistance and durability.

In addition, in Fig. 11 and Fig. 12, an enlarged detailed view of another example of the three-dimensional structure 1 obtained by the manufacturing method of the three-dimensional structure according to this embodiment is illustrated.

As described above, according to the manufacturing method of the three-dimensional structure of this embodiment, it is possible to adjust the portion onto which the covering layer forming ink is applied or the quantity of the covering layer forming ink to be applied, and thus it is possible to more reliably and easily form the covering layer 5 with a desired thickness in a desired portion. For this reason, according to the manufacturing method of the three-dimensional structure of this embodiment, it is possible to easily form the covering layer 5 with desired dimensions according to conditions such as a surface shape or a color of the real image portion 4.

For example, as illustrated in Fig. 11, the covering layer 5 may include a thick portion 52 of which a film thickness is thick, and a thin portion 53 of which a film thickness is thin. Thus, by partially changing the thickness of the covering layer 5, it is possible to easily change the texture (for example, a mat tone or a gloss tone) of the three-dimensional structure 1, or the like. In addition, for example, when a part of the real image portion 4 has a different color, it is possible to easily show spatial effects of the outer surface 15 by partially changing the film thickness of the covering layer 5 according to the color of the real image portion 4.

In addition, for example, as illustrated in Fig. 12, when the surface shape of the real image portion 4 has concavities and convexities, it is possible to form the covering layer 5 to have a shape according to the concave and convex shapes of the real image portion 4. That is, it is possible to set a film thickness a1 of the covering layer 5 in a convex portion 48, and a film thickness a2 of the covering layer 5 in a concave portion 49 to be substantially identical to each other.

Thus, according to the manufacturing method of the three-dimensional structure 1 of this embodiment, it is possible to adjust the film thickness of the covering layer 5 in any way according to the design (according to a pattern of the covering layer forming ink to be applied). For this reason, it is possible to easily obtain the three-dimensional structure 1 with excellent durability against impact, friction, or the like.

In contrast, when the covering layer 5' is disposed by dipping, liquid accumulation occurs in the concave portion 49, and thus a film thickness b2 of the covering layer 5' in the concave portion 49 tends to be thicker than a film thickness b1 of the covering layer 5' in the convex portion 48. Thus, in the method for disposing the covering layer 5' by dipping, it is difficult to form the covering layer 5' to have a uniform film thickness. In addition, the method for disposing the covering layer 5' by dipping depends on the surface shape of the real image portion 4, and thus it is difficult to dispose the covering layer 5' with a desired film thickness in a desired portion. For this reason, in the method for disposing the covering layer 5' by dipping, it is difficult to obtain sufficiently excellent friction resistance or impact resistance.

In addition, according to the manufacturing method of the three-dimensional structure of this embodiment, it is possible to more reliably and easily form the real image portion 4 (the core portion 41 and the outer circumferential portion 42) with a desired thickness in a desired portion according to the design, without being limited by the covering layer 5. In addition, similar to the covering layer 5, it is possible to adjust a film thickness of the real image portion 4 (the core portion 41 and the outer circumferential portion 42) in any way.

In addition, in the related art, the post-process is performed with respect to the three-dimensional structure 1 of a complicated surface shape as illustrated in Fig. 11 or Fig. 12, and thus the covering layer 5 is easily peeled off from the real image portion 4. In contrast, according to the manufacturing method of the three-dimensional structure 1 of this embodiment, as described above, adhesiveness between the covering layer 5 and the real image portion 4 is excellent, and thus even when the surface shape of the three-dimensional structure 1 is complicated, the post-process such as the rough surface machining is easily performed.

As described above, according to the three-dimensional structure forming method of the three-dimensional structure of this embodiment, it is possible to obtain the three-dimensional structure 1 with excellent durability with respect to impact, friction, or the like.

<Ink>
Hereinafter, the ink 2 will be described in detail.

Hereinafter, the covering layer forming ink, the outer circumferential portion forming ink, and the core portion forming ink will be described in sequence.

<Covering Layer Forming Ink>
As described above, the covering layer forming ink is transparent ink.

The covering layer forming ink is configured by a material including a curable resin, and, as necessary, may include a component such as inorganic nanoparticles, a surfactant, an ultraviolet ray absorbing agent, and a solvent.

<Curable Resin>
As the curable resin, for example, a thermosetting resin; various photocurable resins such as a visible light curable resin (in the narrow sense, a photocurable resin) which is cured by light in a visible light region, an ultraviolet ray curable resin, and an infrared ray curable resin; an X-ray curable resin, and the like are included, and a combination of at least one selected therefrom is able to be used. Among them, in particular, from a viewpoint of storage stability of the covering layer forming ink, or the like, the ultraviolet ray curable resin is preferable. In addition, by using the ultraviolet ray curable resin, it is possible to form the unit layer 7 in a relatively short period of time, and thus it is possible to further increase productivity of the three-dimensional structure 1. Furthermore, in this embodiment, the covering layer forming ink includes an ultraviolet ray curable resin.

As the ultraviolet ray curable resin (a polymerizable compound), a material in which addition polymerization or ring-opening polymerization is started by radical species, cationic species, and the like which are generated from a photopolymerization initiator by irradiation of the ultraviolet rays, and thus a polymer is generated, is preferably used. As a polymerization method of the addition polymerization, radicals, cations, anions, metathesis, and coordination polymerization are used. In addition, as a polymerization method of the ring-opening polymerization, cations, anions, radicals, metathesis, and coordination polymerization are used.

As a radical polymerization-type ultraviolet ray curable resin which is cured by a polymerization reaction having radical species as active species, for example, an acryl-based resin, an unsaturated polyester-based resin, and the like are used.

As the acryl-based resin, for example, an ester (meth)acrylate-based resin, an epoxy (meth)acrylate-based resin, a urethane (meth)acrylate-based resin, and the like are used.

As a radical polymerization-type ultraviolet ray curable resin which is cured by a polymerization reaction having cationic species as the active species, for example, an epoxy-based resin, an oxetane-based resin, a vinyl ether-based resin, a silicone-based resin, and the like are used.

As the silicone-based resin, an acrylic silicone-based resin, a polyester silicone resin, an epoxy silicone resin, a mercapto silicone resin, and the like are used.

Among them, in particular, as the ultraviolet ray curable resin, it is preferable to use the acryl-based resin, and it is more preferable to include at least one of urethane (meth)acrylate and epoxy (meth)acrylate. Accordingly, the formed covering layer 5 has high transparency and suitable hardness. For this reason, when the covering layer forming ink including the acryl-based resin is used, it is possible to form the covering layer 5 which is able to more effectively prevent the real image portion 4 from being damaged by friction, impact, or the like, without inhibiting visibility of the real image portion 4. In particular, with at least one of urethane (meth)acrylate and epoxy (meth)acrylate, there are the excellent effects described above.

In addition, a content ratio of the curable resin in the covering layer forming ink is, preferably greater than or equal to 80 mass%, and more preferably greater than or equal to 85 mass%. Accordingly, it is possible to make mechanical strength of the finally obtained core portion 41 especially excellent, and thus it is possible to further increase the mechanical strength of the three-dimensional structure 1.

<Inorganic Nanoparticles>
It is preferable that the covering layer forming ink include inorganic nanoparticles.

Herein, the inorganic nanoparticles are configured by an inorganic material, and an average particle diameter of the particles is greater than or equal to 1 nm and less than or equal to 100 nm.

Furthermore, in the invention, the average particle diameter is a volume-based average particle diameter, and for example, the average particle diameter is able to be obtained by adding a sample to methanol, and by analyzing a dispersion liquid dispersed by an ultrasonic dispersion instrument for 3 minutes using an aperture of 50 micrometers in a particle size distribution measuring instrument (TA-II Type produced by COULTER ELECTRONICS INC.) using a Coulter counter method.

In general, an inorganic nanoparticle is hard compared to an organic nanoparticle, and thus it is difficult for the inorganic nanoparticle to be damaged. Therefore, the covering layer forming ink includes the inorganic nanoparticles, and thus it is possible to further increase the hardness of the covering layer 5. As a result, it is possible to further increase impact resistance or scratch resistance of the three-dimensional structure 1.

It is preferable that the inorganic nanoparticles be particles configured by metal or a metallic compound. Accordingly, it is possible to make the hardness of the formed covering layer 5 suitable.

The metal is not particularly limited, but for example, includes gold, silver, copper, platinum, palladium, nickel, cobalt, iron, manganese, titanium, zirconium, tungsten, molybdenum, chromium, zinc, aluminum, and the like.

The metallic compound, for example, includes various metal oxides such as silica, alumina, titanium oxide, zinc oxide, zirconium oxide, tin oxide, magnesium oxide, and potassium titanate; various metal hydroxides such as magnesium hydroxide, aluminum hydroxide, and calcium hydroxide; various metal nitrides such as silicon nitride, titanium nitride, and aluminum nitride; various metal carbides such as silicon carbide, and titanium carbide; various metal sulfides such as zinc sulfide; various metal carbonates such as calcium carbonate, and magnesium carbonate; various metal sulfates such as calcium sulfate, and magnesium sulfate; various metal silicates such as calcium silicate, and magnesium silicate; various metal phosphates such as calcium phosphate; various metal borates such as aluminum borate, and magnesium borate; a complex compound thereof, and the like.

Among the metals and the metallic compounds, it is preferable that the inorganic nanoparticles be a metal oxide, and it is more preferable that the inorganic nanoparticles include at least one of silicon oxide and aluminum oxide. Accordingly, it is possible to make the hardness of the covering layer 5 more suitable, and thus it is possible to further increase impact resistance and scratch resistance of the three-dimensional structure 1.

In addition, as described above, a shape of the inorganic nanoparticle is not particularly limited, but may be any shape of a grain such as a sphere, an ellipse, and a rectangular body such as a cuboid or a rectangular parallelepiped; a polygonal sheet such as a cylinder, a circular disk, an elliptical disk, and a scale; a needle, and the like, and in particular, the shape of the sphere is preferable. Accordingly, it is possible to especially increase dispersibility of the inorganic nanoparticles in the covering layer forming ink, and thus the entire three-dimensional structure 1 has especially excellent durability against friction, impact, or the like.

In addition, as described above, the average particle diameter of the inorganic nanoparticles may be greater than or equal to 1 nm and less than or equal to 100 nm. In particular, the average particle diameter of the inorganic nanoparticles is, preferably greater than or equal to 5 nm and less than or equal to 50 nm, and more preferably greater than or equal to 10 nm and less than or equal to 30 nm. Accordingly, it is possible to form the covering layer 5 having suitable curing properties, and thus it is possible to obtain the three-dimensional structure 1 having especially excellent durability with respect to friction, impact, or the like.

In addition, when the inorganic nanoparticles are included in the covering layer forming ink, a content ratio of the inorganic nanoparticles in the covering layer forming ink is, preferably greater than or equal to 5 mass% and less than or equal to 30 mass%, and more preferably greater than or equal to 15 mass% and less than or equal to 25 mass%. Accordingly, it is possible to especially increase friction resistance and impact resistance of the three-dimensional structure 1.

<Surfactant>
In addition, it is preferable that the covering layer forming ink include a surfactant.

The covering layer forming ink includes a surfactant, and thus it is possible to make surface tension of the covering layer forming ink suitable, and it is possible to make wettability of the covering layer forming ink suitable. For this reason, it is possible to obtain the three-dimensional structure 1 having especially excellent adhesiveness between the covering layer 5 and the real image portion 4, and thus it is possible to obtain the three-dimensional structure 1 in which occurrence of the interfacial peeling between the covering layer 5 and the real image portion 4 due to friction, impact, or the like is more reliably prevented. Therefore, when the covering layer forming ink includes the surfactant, it is possible to obtain the three-dimensional structure 1 having especially excellent friction resistance and impact resistance.

In addition, it is possible to obtain the three-dimensional structure 1 having especially excellent adhesiveness between the respective unit layers 7, and thus it is possible to more reliably prevent the occurrence of interfacial peeling at an interface between the respective unit layers 7.

The surfactant is not particularly limited, but for example, includes a silicone-based surfactant, a polyoxyethylene-based surfactant, acetylene diol, and the like, and a combination of at least one selected therefrom is able to be used. Among them, in particular, the silicone-based surfactant is preferable. Accordingly, it is possible to obtain the three-dimensional structure 1 having especially excellent friction resistance and impact resistance. In addition, by including the silicone-based surfactant, it is possible to make the outer surface 15 of the covering layer 5 especially smooth. For this reason, it is possible to obtain the three-dimensional structure 1 having especially excellent friction resistance, and especially excellent smoothness of the outer surface 15.

As the silicone-based surfactant, for example, polyester modified silicone, acryl terminal polyester modified silicone, polyether modified silicone, acryl terminal polyether modified silicone, polygrycerol modified silicone, aminopropyl modified silicone, and the like are able to be used. Among them, as the silicone-based surfactant, it is preferable to use polyether modified polydimethylsiloxane or polyester modified polydimethylsiloxane. Accordingly, it is possible to make friction resistance more excellent, and to further improve smoothness of the outer surface 15.

<Ultraviolet Ray Absorbing Agent>
When an ultraviolet ray curable resin is used as the curable resin, it is preferable that the covering layer forming ink include an ultraviolet ray absorbing agent. Accordingly, it is possible to improve weatherablility (light resistance) of the covering layer 5 formed by using the covering layer forming ink and the covering layer forming ink.

As the ultraviolet ray absorbing agent, for example, a combination of at least one selected from a benzotriazole-based material, a benzophenone-based material, a salicylate-based material, an azobenzone-based material, a hindered amine-based material, a benzoylmethane-based material, an oxybenzone-based material, cerium oxide, zinc oxide, and titanium oxide is able to be used.

<Solvent>
The covering layer forming ink may include a solvent. Accordingly, it is possible to suitably adjust viscosity of the covering layer forming ink.

As the solvent, for example, (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; ester acetates such as ethyl acetate, n-propyl acetate, iso-propyl acetate, n-butyl acetate, and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetyl acetone; alcohols such as ethanol, propanol, and butanol, and the like are included, and a combination of at least one selected therefrom is able to be used.

<Other Components>
In addition, the covering layer forming ink may include other components in addition to the materials described above. As such a component, for example, a dispersant; a surfactant; a polymerization initiator; a polymerization accelerator; a penetration enhancer; a wetting agent (a moisturizing agent); a fixing agent; an antifungal agent; an antiseptic agent; an antioxidant; a chelating agent; a pH regulator; a thickener; a filler; an aggregation prevention agent; an antifoaming agent, and the like may be included.

In addition, the viscosity of the covering layer forming ink is, preferably greater than or equal to 10 millipascal-seconds and less than or equal to 25 millipascal-seconds, and more preferably greater than or equal to 15 millipascal-seconds and less than or equal to 20 millipascal-seconds. Accordingly, when the covering layer forming ink is discharged by the ink jet method, it is possible to make discharge stability of the covering layer forming ink especially excellent. Furthermore, herein, the viscosity is a value measured at 25 degrees Celsius by using an E-type viscometer (VISCONIC ELD produced by Tokyo Keiki INC.).

Furthermore, when one three-dimensional structure 1 is formed, a type of covering layer forming ink to be used is not limited to one, and two or more types of covering layer forming ink containing different types of components may be used. For example, two or more types of covering layer forming ink containing different types of curable resins may be used. By using the two or more types of covering layer forming ink, it is possible to show different textures (texture, feel, or the like) in one three-dimensional structure 1 according to a combination of the covering layer forming inks.

<Outer Circumferential Portion Forming Ink>
Next, the outer circumferential portion forming ink will be described in detail.

The outer circumferential portion forming ink is configured by a material including a curable resin and a colorant, and, as necessary, may include a component such as a surfactant, an ultraviolet ray absorbing agent, and a solvent.

As a configuration component of the outer circumferential portion forming ink, the components described in the covering layer forming ink are able to be used.

In addition, the outer circumferential portion forming ink may be configured by a material including a configuration component different from that of the covering layer forming ink, and may be configured by a material including a configuration component identical to that of the covering layer forming ink.

In addition, by using the preferred material described in the covering layer forming ink as the outer circumferential portion forming ink, the same effects as described in the covering layer forming ink are obtained.

In particular, it is preferable that the curable resin included in the outer circumferential portion forming ink be identical to the curable resin included in the covering layer forming ink. Accordingly, it is possible to obtain the three-dimensional structure 1 having more excellent adhesiveness between the outer circumferential portion 42 and the covering layer 5. For this reason, it is possible to especially effectively prevent the occurrence of interfacial peeling at an interface between the covering layer 5 and the outer circumferential portion 42. Therefore, it is possible to obtain the three-dimensional structure 1 having especially excellent durability against friction, impact, or the like.

<Colorant>
In addition, as described above, the outer circumferential portion forming ink includes a colorant. Accordingly, it is possible to more easily obtain the outer circumferential portion 42 of a desired color.

As the colorant, a pigment, a dye, and the like are included. In particular, it is preferable that the colorant include a pigment. Accordingly, it is possible to make weatherablility (light resistance) of the outer circumferential portion 42 excellent.

In addition, as the pigment, either an inorganic pigment or an organic pigment is able to be used.

As the inorganic pigment, for example, carbon blacks (C.I. Pigment Black 7) such as furnace black, lamp black, acetylene black, and channel black, iron oxide, titanium oxide, and the like are included, and a combination of at least one selected therefrom is able to be used.

Among the inorganic pigments, in order to exhibit a preferred white color, titanium oxide is preferable.

As the organic pigment, for example, an azo pigment such as an insoluble azo pigment, a condensed azo pigment, azo lake, and an azo chelate pigment, a polycyclic pigment such as a phthalocyanine pigment, a perylene or perynone pigment, an anthraquinone pigment, a quinacridone pigment, a dioxane pigment, a thioindigo pigment, an isoindolinone pigment, and a quinophthalone pigment, a dye chelate (for example, basic dye-type chelate, acid dye-type chelate, or the like), a dyeing lake (basic dye-type lake, or acid dye-type lake), a nitro pigment, a nitroso pigment, aniline black, a daylight fluorescent pigment, and the like are included, and a combination of at least one selected therefrom is able to be used.

When the outer circumferential portion forming ink includes a pigment, an average particle diameter of the pigment is, preferably less than or equal to 300 nm, and more preferably greater than or equal to 50 nm and less than or equal to 250 nm. Accordingly, it is possible to make dispersion stability of the pigment in the outer circumferential portion forming ink especially excellent. In addition, it is possible to obtain the outer circumferential portion 42 having excellent coloring properties.

In addition, as the dye, for example, an acid dye, a direct dye, a reactive dye, a basic dye, and the like are included, and a combination of at least one selected therefrom is able to be used.

In addition, a content ratio of the colorant in the outer circumferential portion forming ink is preferably greater than or equal to 1 mass% and less than or equal to 20 mass%. Accordingly, it is possible to obtain the outer circumferential portion 42 having especially excellent coloring properties.

In particular, when the outer circumferential portion forming ink includes titanium oxide as the colorant, a content ratio of titanium oxide in the outer circumferential portion forming ink is, preferably greater than or equal to 12 mass% and less than or equal to 18 mass%, and more preferably greater than or equal to 14 mass% and less than or equal to 16 mass%. Accordingly, it is possible to make dimensional accuracy of the outer circumferential portion 42 especially excellent.

<Dispersant>
When the outer circumferential portion forming ink includes a pigment, it is preferable that a dispersant be further included. By including the dispersant, it is possible to make dispersibility of the pigment in the outer circumferential portion forming ink more excellent.

The dispersant is not particularly limited, but for example, includes a dispersant which is commonly used for manufacturing a pigment dispersion liquid such as a polymeric dispersant.

As a specific example of the polymeric dispersant, for example, a polymeric dispersant containing at least one of polyoxyalkylene polyalkylene polyamine, a vinyl-based polymer and copolymer, an acryl-based polymer and copolymer, polyester, polyamide, polyimide, polyurethane, an amino-based polymer, a silicon-containing polymer, a sulfur-containing polymer, a fluorine-containing polymer, and an epoxy resin as a main component is included.

In addition, it is preferable that the viscosity of the outer circumferential portion forming ink satisfy the same conditions described in the covering layer forming ink. Accordingly, the same effects as described in the covering layer forming ink are obtained.

Furthermore, when one three-dimensional structure 1 is formed, a type of outer circumferential portion forming ink to be used is not limited to one, and two or more types of outer circumferential portion forming ink containing different types of components may be used. For example, two or more types of outer circumferential portion forming ink containing different types of colorants may be used. By using the two or more types of outer circumferential portion forming ink, it is possible to broaden a color reproduction region which is able to be shown according to a combination of the outer circumferential portion forming inks.

<Core Portion Forming Ink>
Next, the core portion forming ink will be described in detail.

The core portion forming ink is configured by a material including a curable resin, and, as necessary, may include a component such as a colorant, a surfactant, an ultraviolet ray absorbing agent, and a solvent.

As a configuration component of the core portion forming ink, the components described in the covering layer forming ink and the outer circumferential portion forming ink are able to be used.

In addition, the core portion forming ink may be configured by a material including a configuration component different from that of the covering layer forming ink and the outer circumferential portion forming ink, and may be configured by a material including a configuration component identical to that of the covering layer forming ink and the outer circumferential portion forming ink.

In addition, by using the preferred material described in the outer circumferential portion forming ink and the covering layer forming ink as the core portion forming ink, the same effects as described in the covering layer forming ink and the outer circumferential portion forming ink are obtained.

In particular, it is preferable that the curable resin included in the core portion forming ink be identical to the curable resin included in the outer circumferential portion forming ink. Accordingly, it is possible to obtain the three-dimensional structure 1 having more excellent adhesiveness between the outer circumferential portion 42 and the core portion 41. For this reason, it is possible to especially effectively prevent the occurrence of interfacial peeling at an interface between the outer circumferential portion 42 and the core portion 41. Therefore, it is possible to obtain the three-dimensional structure 1 having especially excellent durability against friction, impact, or the like.

In addition, it is preferable that the core portion forming ink include an acryl-based resin together with the outer circumferential portion forming ink and the covering layer forming ink, and it is more preferable to include at least one of urethane (meth)acrylate and epoxy (meth)acrylate. Accordingly, it is possible to make adhesiveness between the core portion 41 and the outer circumferential portion 42, and adhesiveness between the outer circumferential portion 42 and the covering layer 5 especially excellent, and thus it is possible to obtain the three-dimensional structure 1 having excellent durability against friction, impact, or the like.

Furthermore, when one three-dimensional structure 1 is formed, a type of core portion forming ink to be used is not limited to one, and two or more types of core portion forming ink containing different types of components may be used. For example, transparent core portion forming ink and white core portion forming ink may be used. In this case, it is preferable that a portion formed by the transparent core portion forming ink be disposed on an inner side, and a portion formed by the white core portion forming ink be disposed on an outer side. Accordingly, it is possible to obtain the three-dimensional structure 1 having excellent impact resistance and especially excellent coloring properties.

Second Embodiment

Next, a second embodiment of the manufacturing method of the three-dimensional structure according to the invention, and the three-dimensional structure obtained by the manufacturing method will be described.

Fig. 13 is a flowchart illustrating a procedure of a three-dimensional structure forming process according to the second embodiment.

Hereinafter, the second embodiment of the manufacturing method of the three-dimensional structure according to the invention, and the three-dimensional structure obtained by the manufacturing method will be described with reference to the drawings, but a difference from the embodiment described above will be mainly described, and the description of the same matter will be omitted.

The second embodiment is the same as the first embodiment except that the three-dimensional structure forming process S2 is different from that of the first embodiment.

In the three-dimensional structure forming process S2 of the first embodiment, the covering layer forming ink and the real image portion forming ink are applied, respectively, and then the covering layer forming ink and the real image portion forming ink are cured, and thus the unit layer 7 of one layer is formed.

In contrast, in the three-dimensional structure forming process S2 of the second embodiment, first, the covering layer forming ink is applied and cured (Step S211), and then the outer circumferential portion forming ink is applied and cured (Step S212), and finally, the core portion forming ink is applied and cured (Step S213), and thus the unit layer 7 of one layer is formed.

Hereinafter, the three-dimensional structure forming process S2 of the second embodiment will be described in detail.

<Covering Layer Forming Ink Applying and Curing Processing>
First, in Step S211, covering layer forming ink applying and curing processing is formed.

In Step S211, similar to the first embodiment, the table 32 and the head unit 341 are positioned in a state where the table 32 and the head unit 341 overlap each other in a planar view.

Next, liquid droplets of the covering layer forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the covering layer forming ink is applied onto the second region.

Next, after the covering layer forming ink is applied onto the second region, similar to the first embodiment, the table 32 is moved such that the substrate 31 on the table 32 and the curing device 37 are in a state where the substrate 31 and the curing device 37 overlap each other in a planar view.

Then, the liquid droplets of the covering layer forming ink are irradiated with the ultraviolet rays from the light source 375. Accordingly, the liquid droplets of the covering layer forming ink are cured, and thus a part 5a of the covering layer 5 is obtained.

Furthermore, when there is no data related to the covering layer model 5x in the unit layer data, the covering layer forming ink applying and curing processing (Step S211) is omitted, and then the process proceeds to outer circumferential portion forming ink applying and curing processing (Step S212).

<Outer Circumferential Portion Forming Ink Applying and Curing Processing>
Next, in Step S212, the outer circumferential portion forming ink applying and curing processing is performed.

In Step S212, first, the table 32 and the head unit 341 are positioned in a state where the table 32 and the head unit 341 overlap each other in a planar view.

Next, liquid droplets of the outer circumferential portion forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the outer circumferential portion forming ink is applied onto the outside region of the first region.

Next, after the outer circumferential portion forming ink is applied onto the outside region, similar to the first embodiment, the table 32 is moved such that the substrate 31 on the table 32 and the curing device 37 are in a state where the substrate 31 and the curing device 37 overlap each other in a planar view.

Then, the liquid droplets of the outer circumferential portion forming ink are irradiated with the ultraviolet rays from the light source 375. Accordingly, the liquid droplets of the outer circumferential portion forming ink are cured, and thus a part 42a of the outer circumferential portion 42 is obtained.

Furthermore, when there is no data related to the outer circumferential portion model 42x in the unit layer data, the outer circumferential portion forming ink applying and curing processing (Step S212) is omitted, and then the process proceeds to core portion forming ink applying and curing processing (Step S213).

In addition, the outer circumferential portion forming ink applying and curing processing (Step S212) may be started before the covering layer forming ink applying and curing processing (Step S211) described above is ended. For example, the outer circumferential portion forming ink may be applied while curing the covering layer forming ink which is previously applied. In this case, for example, a three-dimensional structure forming apparatus (not illustrated) in which the head unit 341 for discharging the ink 2 and the light source 375 for radiating the ultraviolet rays are integrally disposed in the carriage 34 may be used.

<Core Portion Forming Ink Applying and Curing Processing>
Next, in Step S213, the core portion forming ink applying and curing processing is performed.

In Step S213, first, the table 32 and the head unit 341 are positioned in a state where the table 32 and the head unit 341 overlap each other in a planar view.

Next, liquid droplets of the core portion forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the core portion forming ink is applied onto the inside region of the first region.

Next, after the core portion forming ink is applied onto the inside region, similar to the first embodiment, the table 32 is moved such that the substrate 31 on the table 32 and the curing device 37 are in a state where the substrate 31 and the curing device 37 overlap each other in a planar view.

Then, the liquid droplets of the core portion forming ink are irradiated with the ultraviolet rays from the light source 375. Accordingly, the liquid droplets of the core portion forming ink are cured, and thus a part 41a of the core portion 41 is obtained.

Furthermore, when there is no data related to the core portion model 41x in the unit layer data, the core portion forming ink applying and curing processing (Step S213) is omitted, and then the process proceeds to Step S23.

In addition, the core portion forming ink applying and curing processing (Step S213) may be started before the covering layer forming ink applying and curing processing (Step S211) or the outer circumferential portion forming ink applying and curing processing (Step S212) described above is ended.

Through Steps (S211, S212, and S213) described above, the unit layer 7 of one layer is formed.

Then, similar to the first embodiment, it is determined whether or not the entire unit layer data has been processed (Step S23). The determination in Step S23 is the same as the first embodiment described above.

According to the three-dimensional structure forming process S2 of the second embodiment as described above, similar to the first embodiment, it is possible to obtain the three-dimensional structure 1 as illustrated in Figs. 1A and 1B.

In addition, as described above, in the second embodiment, when the unit layer 7 of one layer is formed, a part 5a of the covering layer 5 is formed, and then a part 42a of the outer circumferential portion 42 and a part 41a of the core portion 41 are formed. Thus, by forming the unit layer 7 of one layer, it is possible to further increase dimensional accuracy of each

part

5a, 41a, and 42a. In addition, it is possible to further prevent the liquid droplets of the covering layer forming ink, the outer circumferential portion forming ink, and the core portion forming ink from being unintentionally mixed. For this reason, it is possible to make the interface between the respective portions (the covering layer 5, the outer circumferential portion 42, and the core portion 41) clear.

Third Embodiment

Next, a third embodiment of the manufacturing method of the three-dimensional structure according to the invention, and the three-dimensional structure obtained by the manufacturing method will be described.

Fig. 14 is a flowchart illustrating a procedure of a three-dimensional structure forming process according to the third embodiment.

Hereinafter, the third embodiment of the manufacturing method of the three-dimensional structure according to the invention, and the three-dimensional structure obtained by the manufacturing method will be described with reference to the drawings, but a difference from the embodiment described above will be mainly described, and the description of the same matter will be omitted.

The third embodiment is the same as the second embodiment except that the three-dimensional structure forming process S2 is different from that of the second embodiment.

In the three-dimensional structure forming process S2 of the second embodiment, first, the covering layer forming ink is applied and cured (Step S211), and then the outer circumferential portion forming ink is applied and cured (Step S212), and finally, the core portion forming ink is applied and cured (Step S213), and thus the unit layer 7 of one layer is formed.

In contrast, in the third embodiment, as illustrated in Fig. 14, first, the core portion forming ink is applied and cured (Step S213), and then the outer circumferential portion forming ink is applied and cured (Step S212), and finally, the covering layer forming ink is applied and cured (Step S211), and thus the unit layer 7 of one layer is formed.

Hereinafter, the three-dimensional structure forming process S2 of the third embodiment will be described in detail.

<Core Portion Forming Ink Applying and Curing Processing>
First, in Step S213, similar to the second embodiment, the core portion forming ink applying and curing processing is performed.

Similar to the second embodiment, the liquid droplets of the core portion forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the core portion forming ink is applied onto the inside region of the first region. Then, the liquid droplets of the core portion forming ink are irradiated with the ultraviolet rays, and thus the liquid droplets of the core portion forming ink are cured. Accordingly, a part 41a of the core portion 41 is obtained.

Furthermore, when there is no data related to the core portion model 41x in the unit layer data, the core portion forming ink applying and curing processing (Step S213) is omitted, and then the process proceeds to the outer circumferential portion forming ink applying and curing processing (Step S212).

<Outer Circumferential Portion Forming Ink Applying and Curing Processing>
Next, in Step S212, similar to the second embodiment, the outer circumferential portion forming ink applying and curing processing is formed.

Similar to the second embodiment, the liquid droplets of the outer circumferential portion forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the outer circumferential portion forming ink is applied onto the outside region of the first region. Then, the liquid droplets of the outer circumferential portion forming ink are irradiated with the ultraviolet rays, and thus the liquid droplets of the outer circumferential portion forming ink are cured. Accordingly, a part 42a of the outer circumferential portion 42 is obtained.

Furthermore, when there is no data related to the outer circumferential portion model 42x in the unit layer data, the outer circumferential portion forming ink applying and curing processing (Step S212) is omitted, and then the process proceeds to the covering layer forming ink applying and curing processing (Step S211).

In addition, the outer circumferential portion forming ink applying and curing processing (Step S212) may be started before the core portion forming ink applying and curing processing (Step S213) described above is ended. For example, the outer circumferential portion forming ink may be applied while curing the core portion forming ink which is previously applied.

<Covering Layer Forming Ink Applying and Curing Processing>
Next, in Step S211, similar to the second embodiment, the covering layer forming ink applying and curing processing is performed.

Similar to the second embodiment, the liquid droplets of the covering layer forming ink are discharged from the nozzle (not illustrated) provided in the liquid droplet discharging head 345, and the covering layer forming ink is applied onto the second region. Then, the liquid droplets of the covering layer forming ink are irradiated with the ultraviolet rays, and thus the liquid droplets of the covering layer forming ink are cured. Accordingly, a part 5a of the covering layer 5 is obtained.

Furthermore, when there is no data related to the covering layer model 5x in the unit layer data, the covering layer forming ink applying and curing processing (Step S211) is omitted, and then the process proceeds to Step S23.

In addition, the covering layer forming ink applying and curing processing (Step S211) may be started before the core portion forming ink applying and curing processing (Step S213) and the outer circumferential portion forming ink applying and curing processing (Step S212) described above are ended.

Through Steps (S213, S212, and S211) described above, the unit layer 7 of one layer is formed.

Then, similar to the embodiment described above, it is determined whether or not the entire unit layer data has been processed (Step S23). The determination in Step S23 is the same as the embodiment described above.

According to the three-dimensional structure forming process S2 of the third embodiment as described above, similar to the embodiment described above, it is possible to obtain the three-dimensional structure 1 as illustrated in Figs. 1A and 1B.

As described above, the preferred embodiments of the invention is described, but the invention is not limited thereto.

For example, any manufacturing process may be added to the manufacturing method of the three-dimensional structure according to the invention. In addition, the three-dimensional structure of the invention may be manufactured by the manufacturing method of the three-dimensional structure according to the invention, and each of the portions configuring the three-dimensional structure is able to be replaced by any configuration enabling the same function to be realized. In addition, any configuration may be added to the three-dimensional structure of the invention.

More specifically, for example, in the embodiment described above, a case where the ink applying processing and the curing processing are repeated is described, but the curing processing may not be repeated. For example, after forming a laminated body including a plurality of layers which is not cured, the curing processing may be collectively performed.

In addition, in the manufacturing method according to the invention, as necessary, a pre-processing process, an intermediate-processing process, and a post-processing process may be performed. For example, as the pre-processing process, a cleaning process of the table (the support), and the like are included.

In addition, in the embodiment described above, a case where the ink applying processing is performed by the ink jet method is mainly described, but the ink applying processing may be performed by using other methods (for example, other printing methods).

In addition, in the embodiment described above, the covering layer for configuring the three-dimensional structure obtained through the three-dimensional structure forming process is formed to be thicker by a thickness which is ablated in the post-process described later, and for example, when the post-process is not performed, the thickness of the covering layer may not be formed to be thicker than planned. That is, when each of the unit layers is formed, the process in which the film thickness of the covering layer is formed to be thicker by the thickness which is ablated in the post-process may be omitted.

In addition, in the embodiment described above, when the three-dimensional structure is manufactured, the three-dimensional structure forming system including the three-dimensional structure forming apparatus and the computer is used, but an apparatus integrated with the three-dimensional structure forming apparatus and the computer may be used.

In addition, an intended purpose of the three-dimensional structure according to the invention is not particularly limited, but for example, an aesthetic object and an exhibit such as a doll, or a figure; a medical instrument such as an implant, and the like are included.

In addition, the three-dimensional structure of the invention may be applied to any one of a prototype, a mass-produced product, and a tailor-made product.

In addition, the entire shape of the three-dimensional structure of the invention, in the embodiment described above, is cubic, but the shape of the three-dimensional structure is not limited thereto. For example, the shape of the three-dimensional structure may be spherical, rectangular parallelepiped, amorphous, or the like. In addition, the three-dimensional structure may have an internal structure, or an inner cavity.

1 Three-dimensional structure
15 Outer surface
2 Ink
4 Real image portion
41 Core portion
41a Part (part of core portion 41)
42 Outer circumferential portion
42a Part (part of outer circumferential portion 42)
44 Outer surface (outer surface of core portion)
45 Outer surface (outer surface of outer circumferential portion)
46 Corner portion
47 Side surface portion
48 Convex portion
49 Concave portion
5 Covering layer
5a Part (part of covering layer 5)
52 Thick portion
53 Thin portion
7 Unit layer
7A First unit layer
7B Second unit layer
7C Third unit layer
75 Coating layer
1x Three-dimensional structure model
15x Outer surface
4x Real image portion model
41x Core portion model
42x Outer circumferential portion model
44x Outer surface (outer surface of core portion model)
45x Outer surface (outer surface of outer circumferential portion model)
5x Covering layer model
7x Unit layer model
100 Three-dimensional structure manufacturing system (three-dimensional structure forming system)
20 Computer
21 Control unit
22 CPU
23 Storage unit
231 Control program
232 Data developing unit
24 Reception unit
25 Image creation unit
26 Monitor
261 Image display region
27 Keyboard
28 Input and output interface (I/F)
29 Data bus
30 Three-dimensional structure manufacturing apparatus (three-dimensional structure forming apparatus)
31 Substrate
31a Drawing surface
32 Table
32a Upper surface
33 Table movement device
331 Base
331a Upper surface
332a Guide rail
332b Guide rail
335 Table movement motor
336 Table position detecting device
34 Carriage
341 Head unit
345 Liquid droplet discharging head
348 Tank
349 Tube
35 Drive control unit
351 Motor control unit
353 Position detection control unit
355 Discharge control unit
357 Exposure control unit
36 Carriage movement device
361 Guide member
362a Supporting pole
362b Supporting pole
363 Guide rail
364a Guide rail
364b Guide rail
365 Carriage movement motor
366 Carriage position detecting device
37 Curing device
371 Supporting pole
371a Beam portion
375 Light source
a1, a2, a3, and a4 Film thickness
5' Covering layer (covering layer disposed by dipping)
60 Three-dimensional object
61 Outer surface
62 Concave portion
63 Convex portion
65 Protective layer
b1, b2, b3, and b4 Film thickness

Claims

A manufacturing method of a three-dimensional structure for manufacturing the three-dimensional structure obtained by laminating a unit layer which is formed by applying an ink including a curable resin and by curing the ink,
wherein the three-dimensional structure includes an outer circumferential portion, and a transparent covering layer for covering the outer circumferential portion, and
at the time of forming the unit layer, an outer circumferential portion forming ink is applied onto a first region corresponding to the outer circumferential portion, a covering layer forming ink is applied onto a second region corresponding to the covering layer, and the outer circumferential portion forming ink and the covering layer forming ink are cured.
The manufacturing method of the three-dimensional structure according to Claim 1,
wherein at the time of forming the unit layer, the outer circumferential portion forming ink is applied onto the first region, the covering layer forming ink is applied onto the second region, and then the outer circumferential portion forming ink and the covering layer forming ink are cured.
The manufacturing method of the three-dimensional structure according to Claim 1,
wherein at the time of forming the unit layer, the covering layer forming ink is cured while being applied onto the second region, and then the outer circumferential portion forming ink is cured while being applied onto the first region.
The manufacturing method of the three-dimensional structure according to Claim 1,
wherein at the time of forming the unit layer, the outer circumferential portion forming ink is cured while being applied onto the first region, and then the covering layer forming ink is cured while being applied onto the second region.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 4,
wherein the covering layer forming ink contains inorganic nanoparticles.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 5,
wherein the covering layer forming ink contains a silicone-based surfactant.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 6,
wherein the curable resin contained in the covering layer forming ink is a photocurable resin.
The manufacturing method of the three-dimensional structure according to Claim 7,
wherein the photocurable resin is an acryl-based resin.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 8,
wherein the acryl-based resin contains at least one of urethane (meth)acrylate and epoxy (meth)acrylate.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 9,
wherein a post-process is performed with respect to the covering layer.
The manufacturing method of the three-dimensional structure according to Claim 10,
wherein the post-process is rough surface machining.
The manufacturing method of the three-dimensional structure according to Claim 10 or 11,
wherein at the time of forming the unit layer, the covering layer is formed to be thicker by a thickness which is ablated in the post-process.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 12,
wherein an average thickness of the covering layer is greater than or equal to 10 micrometers and less than or equal to 1000 micrometers.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 13,
wherein an average film thickness of the outer circumferential portion is greater than or equal to 30 micrometers and less than or equal to 200 micrometers.
The manufacturing method of the three-dimensional structure according to any one of Claims 1 to 14,
wherein the outer circumferential portion forming ink contains a colorant.
A three-dimensional structure which is manufactured by the manufacturing method of the three-dimensional structure according to any one of Claims 1 to 15.