WO2016121217A1 - 3次元造形物の製造方法、3次元造形物の製造装置、3次元造形物及び造形材料 - Google Patents
3次元造形物の製造方法、3次元造形物の製造装置、3次元造形物及び造形材料 Download PDFInfo
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- WO2016121217A1 WO2016121217A1 PCT/JP2015/083504 JP2015083504W WO2016121217A1 WO 2016121217 A1 WO2016121217 A1 WO 2016121217A1 JP 2015083504 W JP2015083504 W JP 2015083504W WO 2016121217 A1 WO2016121217 A1 WO 2016121217A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/10—Processes of additive manufacturing
- B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
- B29C64/209—Heads; Nozzles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/205—Means for applying layers
- B29C64/218—Rollers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/20—Apparatus for additive manufacturing; Details thereof or accessories therefor
- B29C64/245—Platforms or substrates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
- B29C64/30—Auxiliary operations or equipment
- B29C64/307—Handling of material to be used in additive manufacturing
- B29C64/321—Feeding
- B29C64/336—Feeding of two or more materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y30/00—Apparatus for additive manufacturing; Details thereof or accessories therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y70/00—Materials specially adapted for additive manufacturing
- B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/16—Fillers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2475/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as filler
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2509/00—Use of inorganic materials not provided for in groups B29K2503/00 - B29K2507/00, as filler
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
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- G—PHYSICS
- G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
- G09B—EDUCATIONAL OR DEMONSTRATION APPLIANCES; APPLIANCES FOR TEACHING, OR COMMUNICATING WITH, THE BLIND, DEAF OR MUTE; MODELS; PLANETARIA; GLOBES; MAPS; DIAGRAMS
- G09B23/00—Models for scientific, medical, or mathematical purposes, e.g. full-sized devices for demonstration purposes
- G09B23/28—Models for scientific, medical, or mathematical purposes, e.g. full-sized devices for demonstration purposes for medicine
- G09B23/30—Anatomical models
Definitions
- the present invention provides a three-dimensional structure formed by a powder lamination method, which is a kind of modeling method using a 3D printer, a manufacturing method thereof, a manufacturing apparatus thereof, and a three-dimensional structure formed by a powder lamination method. It relates to the modeling material to be used.
- the powder lamination method which is a kind of modeling method using a 3D printer, discharges and solidifies a modeling liquid having a function of an adhesive on a flatly arranged modeling material to form one layer of a three-dimensional modeled object. It is a method of forming a three-dimensional structure by forming and laminating this layer.
- Patent Document 1 describes a technique using gypsum powder as a main material of a modeling material.
- the present invention has been made in view of such problems, and in forming a three-dimensional structure by the powder lamination method, the strength is high, and the image is soft and can be imaged by an ultrasonic diagnostic apparatus. It aims at enabling it to form a three-dimensional structure.
- the manufacturing method of the three-dimensional structure of the present invention includes a step of forming a three-dimensional structure by a powder lamination method using a modeling material in which urethane resin powder is mixed with gypsum powder, and the three-dimensional structure. And impregnating with urethane resin.
- Another aspect of the method for producing a three-dimensional structure of the present invention further includes a step of immersing the three-dimensional structure in an aqueous medium after the step of impregnating the urethane resin is completed.
- an antiseptic / antifungal agent is dissolved in the aqueous medium.
- the other aspect in the manufacturing method of the three-dimensional structure according to the present invention is the hollow of the three-dimensional structure after the step of impregnating the urethane resin and before the step of immersing in the aqueous medium.
- the method further includes forming a soft resin softer than the three-dimensional structure in the region.
- the other aspect in the manufacturing method of the three-dimensional structure according to the present invention is such that the soft resin is formed using a urethane resin as a main material.
- the other aspect in the manufacturing method of the three-dimensional structure according to the present invention is such that, in addition to the main material, the soft resin projects the soft resin formed in the hollow region in ultrasonic imaging. It is formed including an ultrasonic scattering material.
- the urethane resin powder has a weight ratio of 5% to 60% with respect to the total weight of the modeling material.
- the present invention provides a three-dimensional structure manufacturing apparatus that performs the above-described three-dimensional structure manufacturing method, a three-dimensional structure manufactured by the above-described three-dimensional structure manufacturing method, and the above-described three-dimensional structure.
- the modeling material used with the manufacturing method of a molded article is included.
- a three-dimensional structure having high strength can be formed in the formation of the three-dimensional structure by the powder lamination method. Furthermore, according to the present invention, it is possible to form a soft three-dimensional structure. In addition, according to the present invention, it is possible to form a three-dimensional structure that can be imaged by an ultrasonic diagnostic apparatus. For example, if the technique of the present invention is applied to the medical field, it is possible to form a three-dimensional structure that reproduces an individual patient's organ in a form closer to the real object. And can be used for surgical training using an ultrasonic diagnostic apparatus, and the quality of medical care can be improved.
- FIG. 1 is a block diagram showing an example of a schematic configuration of a three-dimensional structure manufacturing apparatus according to the first embodiment of the present invention.
- FIG. 2 is a flowchart illustrating an example of a processing procedure in the three-dimensional structure manufacturing method executed by the three-dimensional structure manufacturing apparatus according to the first embodiment of the present invention.
- FIG. 3 is a schematic diagram showing an example of a specific operation of the three-dimensional structure forming apparatus shown in FIG.
- FIG. 4 shows the first embodiment of the present invention, and a three-dimensional structure manufactured after changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material shown in FIG. 1 (after immersion in an aqueous medium). It is a characteristic view which shows the result of a tensile strength test.
- FIG. 1 is a block diagram showing an example of a schematic configuration of a three-dimensional structure manufacturing apparatus according to the first embodiment of the present invention.
- FIG. 2 is a flowchart illustrating an example of a processing procedure in the three
- FIG. 5 shows the first embodiment of the present invention, and a three-dimensional structure (before urethane resin impregnation) manufactured by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material shown in FIG. It is a characteristic view which shows the result of the rubber hardness test of a three-dimensional structure (after urethane resin impregnation) and a three-dimensional structure (after aqueous medium immersion).
- FIG. 6 shows the first embodiment of the present invention, and retains the shape of the three-dimensional structure manufactured by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material shown in FIG. It is a figure which shows the propriety of.
- FIG. 6 shows the first embodiment of the present invention, and retains the shape of the three-dimensional structure manufactured by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material shown in FIG. It is a figure which shows the propriety of.
- FIG. 7 is a block diagram which shows an example of schematic structure of the manufacturing apparatus of the three-dimensional structure based on the 2nd Embodiment of this invention.
- FIG. 8 is a flowchart which shows an example of the process sequence in the manufacturing method of the three-dimensional structure performed with the manufacturing apparatus of the three-dimensional structure based on the 2nd Embodiment of this invention.
- FIG. 9A is a diagram illustrating a three-dimensional structure obtained by ultrasonic imaging.
- FIG. 9B shows a comparative example, and is an external view of a three-dimensional structure manufactured without forming a hollow region (that is, with a modeling material in which all of the soft resin is mixed with powder without forming a soft resin). is there.
- FIG. 9A is a diagram illustrating a three-dimensional structure obtained by ultrasonic imaging.
- FIG. 9B shows a comparative example, and is an external view of a three-dimensional structure manufactured without forming a hollow region (that is, with a modeling material in which all of the
- FIG. 9C shows a comparative example, in which the three-dimensional structure shown in FIG. 9B manufactured without forming a hollow region (that is, with a modeling material in which all of the soft resin part is mixed with powder without forming a soft resin) is produced. It is a figure which shows the result of having carried out ultrasonic imaging
- FIG. 9D is a diagram illustrating a result of ultrasonic imaging of the three-dimensional structure illustrated in FIG. 9A in which the soft resin is formed in the hollow region according to the second embodiment of this invention.
- FIG. 1 is a block diagram showing an example of a schematic configuration of a three-dimensional structure manufacturing apparatus 100 according to the first embodiment of the present invention.
- the three-dimensional structure manufacturing apparatus 100 includes an information input device 110, an information processing / control device 120, a three-dimensional structure formation apparatus 130, a first heat treatment apparatus 140, and urethane.
- a resin impregnation device 150, a second heat treatment device 160, and an aqueous medium immersion device 170 are included.
- the information input device 110 is a device that inputs various types of information including various types of data to the information processing / control device 120.
- the information input device 110 may be constituted by, for example, a keyboard and a mouse in a personal computer, or may be a communication interface for connecting to a computer network.
- the information processing / control device 120 is a device that processes various types of information input from the information input device 110 and controls the operation of the three-dimensional structure manufacturing apparatus 100 in an integrated manner. For example, the information processing / control device 120 controls each device (130 to 170) in the three-dimensional structure manufacturing device 100 based on various types of information input from the information input device 110.
- the three-dimensional structure forming apparatus 130 forms a three-dimensional structure 300-1 by a powder lamination method using a modeling material 200 in which urethane resin powder is mixed with gypsum powder under the control of the information processing / control apparatus 120. It is a device to do.
- the modeling material 200 is further mixed with a gypsum powder and an antiseptic / antifungal agent in addition to the urethane resin powder.
- the molding material 200 in the present embodiment is a mixture of a gypsum powder and a urethane resin powder and an antiseptic / antifungal agent.
- a silver-containing amorphous glass powder is used as an antiseptic / antifungal agent contained in the modeling material 200.
- the urethane resin powder contained in the modeling material 200 preferably has a weight ratio of 5% to 60% with respect to the total weight of the modeling material 200. This is because when the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is less than 5%, the plaster becomes dominant and the finished three-dimensional model 300 becomes brittle due to insufficient strength, In addition, when the weight ratio of the urethane resin powder to the total weight of the modeling material 200 exceeds 60%, when the three-dimensional model 300 that is a finished product is stored (stored in an aqueous medium), This is because there is a problem that the shape cannot be maintained and collapses.
- the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is in the range of 20% to 40%.
- the antiseptic / antifungal agent contained in the modeling material 200 preferably has a weight ratio with respect to the total weight of the modeling material 200 in the range of 0.1% to 5%. This is because when the weight ratio of the antiseptic / antifungal agent to the total weight of the modeling material 200 is less than 0.1%, the antiseptic / antifungal function of the three-dimensional model 300 that is the finished product becomes insufficient. This is because it occurs.
- the gypsum powder contained in the modeling material 200 preferably has a weight ratio of 35% to 94.9% with respect to the total weight of the modeling material 200.
- the first heat treatment apparatus 140 is an apparatus that heat-treats the three-dimensional structure 300-1 formed by the three-dimensional structure formation apparatus 130 at a predetermined temperature (first heat treatment) according to the control of the information processing / control apparatus 120. It is. In the present embodiment, the first heat treatment apparatus 140 first heat-treats the three-dimensional structure 300-1 at a temperature of about 50 ° C. for 30 minutes to 1 hour, and then at a temperature of about 80 ° C. Heat treatment is performed for 30 minutes to 1 hour. In this example, the first heat treatment by the first heat treatment apparatus 140 causes the entire water content of the three-dimensional structure 300-1 to be removed to fix the gypsum particles.
- the urethane resin impregnation device 150 is a device for impregnating the urethane resin into the three-dimensional structure 300-2 heat-treated by the first heat treatment device 140 in accordance with the control of the information processing / control device 120.
- the impregnation method by the urethane resin impregnation apparatus 150 for example, a form in which the urethane resin is impregnated using a brush, a form in which the urethane resin is sprayed and impregnated, or a container filled with the urethane resin is 3 It is possible to adopt a form in which the three-dimensional structure 300-2 is immersed and impregnated.
- the urethane resin used in the urethane resin impregnation apparatus 150 is not particularly limited as long as it can be cured with a liquid urethane resin, but the operation is simplified by using a one-component moisture-curing urethane resin. This is preferable.
- a urethane resin obtained by diluting a mixture of a polyol and a polyisocyanate with butyl acetate, ethyl acetate, or the like is used as a material of the urethane resin used in the urethane resin impregnation apparatus 150.
- the second heat treatment apparatus 160 heat-treats the three-dimensional structure 300-3, which has been subjected to the urethane resin impregnation treatment by the urethane resin impregnation apparatus 150, at a predetermined temperature (second heat treatment) in accordance with the control of the information processing / control apparatus 120. It is a device to do.
- the second heat treatment apparatus 160 first heat-treats the three-dimensional structure 300-3 at a temperature of 15 ° C. or more for 12 to 24 hours, and then performs a temperature of 80 ° C. Heat treatment is performed for about 2 hours.
- the urethane resin impregnated by the urethane resin impregnation apparatus 150 is cured by the second heat treatment by the second heat treatment apparatus 160.
- the aqueous medium immersion apparatus 170 is an apparatus for immersing the three-dimensional structure 300-4 heat-treated by the second heat treatment apparatus 160 in the aqueous medium under the control of the information processing / control apparatus 120.
- the aqueous medium is not particularly limited as long as the strength and softness of the three-dimensional structure 300 are not impaired, but water, physiological saline, buffer solution, aqueous organic solvent such as glycerin and ethylene glycol, or A mixture of these can be mentioned, and a water-soluble substance can also be dissolved in them.
- an antiseptic / antifungal agent can be added to the aqueous medium described above.
- the antiseptic / antifungal agent has antiseptic / antifungal functions for the three-dimensional structure 300-4 and an aqueous medium, and does not affect the strength and softness of the three-dimensional structure 300.
- an antifungal agent in consideration of handling, surgical training, etc., those with low irritation are preferable, such as hydrogen peroxide, hypochlorous acid, sodium hypochlorite, phenoxyethanol, benzoic acid
- examples thereof include sodium acid, paraoxybenzoic acid ester, and salts thereof, and can be used at appropriate concentrations that exhibit antiseptic and antifungal functions, respectively.
- the aqueous medium immersion device 170 for example, immerses the three-dimensional structure 300-4 in an aqueous medium having a temperature of 80 ° C. to 95 ° C. for about 1 hour.
- the three-dimensional structure manufacturing apparatus 100 performs a process of taking out the three-dimensional structure 300-5 from the aqueous medium immersion device 170.
- FIG. 1 a mode in which two heat treatment apparatuses, a first heat treatment apparatus 140 and a second heat treatment apparatus 160 are provided, is shown, but in this embodiment, the present invention is limited to this aspect. Instead, for example, an embodiment in which one heat treatment apparatus is provided and both the first heat treatment by the first heat treatment apparatus 140 and the second heat treatment by the second heat treatment apparatus 160 are performed in this one heat treatment apparatus is also performed in this embodiment. Applicable to form. In addition, in the case where the three-dimensional structure 300 is naturally dried over a long period of time, an embodiment in which either one or both of the first heat treatment apparatus 140 and the second heat treatment apparatus 160 is not provided is also the present embodiment. It is applicable to.
- FIG. 2 is a flowchart showing an example of a processing procedure in the method for manufacturing a three-dimensional structure executed by the three-dimensional structure manufacturing apparatus 100 according to the first embodiment of the present invention. The processing of the flowchart shown in FIG. 2 will be described below with reference to FIG.
- the information input device 110 of FIG. 1 performs a process of inputting three-dimensional modeling data to the information processing / control device 120. Then, for example, the information processing / control device 120 processes the three-dimensional modeling data input from the information input device 110 to obtain slice data of N layers. In addition, the information processing / control device 120 sets the number N of layers. Thereafter, the information processing / control device 120 transmits information related to the slice data of each layer of the three-dimensional modeling data, information related to the number N of the three-dimensional modeling data, and the like to the three-dimensional modeling object forming device 130.
- the three-dimensional structure forming apparatus 130 that has received the information related to the slice data of each layer of the three-dimensional modeling data and the information related to the number N of the three-dimensional modeling data from the information processing / control apparatus 120 is indicated by a broken line in FIG.
- the following steps S2 to S6 surrounded by a frame are performed.
- the three-dimensional structure forming apparatus 130 in FIG. 1 sets 1 to the stacking number n indicating the layer to be formed.
- step S3 of FIG. 2 the three-dimensional structure forming device 130 of FIG. 1 supplies the nth layer of the forming material 200 to the modeling region portion according to the control of the information processing / control device 120.
- step S4 of FIG. 2 the three-dimensional structure forming device 130 of FIG. 1 performs the nth layer based on the slice data of the nth layer of the three-dimensional structure data according to the control of the information processing / control device 120.
- a modeling liquid having an adhesive function is applied to a predetermined position of the modeling material 200.
- step S5 of FIG. 2 the three-dimensional structure forming apparatus 130 of FIG. 1 determines whether or not the currently set stacking number n is smaller than the stacking number N set in step S1.
- step S5 if the currently set stacking number n is smaller than the stacking number N set in step S1 (S5 / YES), the processing on the slice data of all layers is still complete. If not, the process proceeds to step S6 in FIG.
- the three-dimensional structure forming apparatus 130 in FIG. 1 adds 1 to the stacking number n indicating the formation target layer to change the stacking number n indicating the formation target layer. Then, it returns to step S3 and performs the process based on the changed stacking number n. That is, in the process of the flowchart shown in FIG. 2, the processes in steps S3 to S6 are repeated for the number N of layers set in step S1.
- step S5 when the currently set stacking number n is not smaller than the stacking number N set in step S1 (S5 / NO), the processing on the slice data of all layers is completed. The process proceeds to step S7 in FIG.
- step S7 in FIG. 2 the specific operation of the three-dimensional structure forming apparatus 130 in steps S2 to S6 described above will be described.
- FIG. 3 is a schematic diagram showing an example of a specific operation of the three-dimensional structure forming apparatus 130 shown in FIG. Specifically, FIG. 3 shows an example of a specific operation of the three-dimensional structure forming apparatus 130 when forming the three-dimensional structure 300-1 by the powder lamination method.
- the three-dimensional structure forming apparatus 130 includes a roller 131, a printer head 132, a modeling material storage unit 133, a piston 134, a modeling region unit 135, a piston 136, and a modeling material discharge unit 137. It is comprised.
- the roller 131 performs an operation for supplying the modeling material 200 for each layer to the modeling region part 135.
- the printer head 132 applies a modeling liquid having a function of an adhesive to a predetermined position of the modeling material 200 of each layer supplied to the modeling area unit 135 based on slice data of each layer of the three-dimensional modeling data.
- the printer head 132 is assumed to operate integrally with the roller 131.
- the modeling material storage unit 133 stores the modeling material 200 used when forming the three-dimensional model 300-1 by the powder lamination method.
- the piston 134 operates when supplying the modeling material 200 stored in the modeling material storage unit 133 to the modeling region unit 135.
- the modeling area part 135 is an area part for forming the three-dimensional structure 300-1.
- the piston 136 operates when forming the three-dimensional structure 300-1.
- the modeling material discharge unit 137 is for discharging excess modeling material 200 out of the modeling material 200 supplied to the modeling region unit 135.
- the roller 131 and the printer head 132 are located on the left side of the modeling material storage unit 133.
- the roller 131 moves to the right side of the sheet along with the printer head 132 while rotating.
- a predetermined amount of the modeling material 200 stored in the modeling material storage unit 133 is supplied to the modeling region unit 135.
- the roller 131 passes through the modeling area unit 135 together with the printer head 132, the modeling material 200 supplied to the modeling area unit 135 is stretched and flattened as shown in process P3 of FIG. A first layer of modeling material 200 is laid. Furthermore, as shown in process P ⁇ b> 3 in FIG. 3, excess modeling material 200 generated when the modeling material 200 is stretched by the roller 131 is discharged to the modeling material discharge unit 137. In the process P3 of FIG. 3, the roller 131 and the printer head 132 are shown moving to the right side of the modeling material discharge unit 137.
- the printer head 132 converts the slice data of the first layer of the three-dimensional modeling data. Based on this, the modeling liquid 201 having the function of an adhesive is applied to a predetermined position of the modeling material 200 of the first layer. At this time, since various colors can be applied to the modeling liquid 201 applied from the printer head 132, for example, when the three-dimensional model 300-1 relating to the patient's organ is formed, the modeling liquid 201 has a shape closer to the actual one. A three-dimensional structure can be formed, and the affected part (lesioned part) can also be grasped.
- step S4 in FIG. 3 corresponds to step S4 in FIG. Then, the modeling based on the slice data of the first layer of the three-dimensional modeling data is completed by the steps shown in the process P1 in FIG. 3 to the process P4 in FIG.
- the printer head 132 and the roller 131 move to the left position of the modeling material storage unit 133 as shown in process P5 of FIG.
- the piston 134 rises by a predetermined amount to push up the modeling material 200 stored in the modeling material storage unit 133, and the piston 136 descends by a predetermined amount to the modeling region unit 135.
- a space for laying the second layer of modeling material 200 is created. Then, it transfers to the process shown to the process P1 of FIG. 3, and modeling of the 2nd layer or later is performed.
- the process proceeds to step S7 in FIG.
- the first heat treatment apparatus 140 in FIG. 1 predetermines the three-dimensional structure 300-1 formed by the three-dimensional structure formation apparatus 130 in accordance with the control of the information processing / control apparatus 120.
- Heat treatment (first heat treatment) is performed at a temperature of
- the first heat treatment apparatus 140 first heat-treats the three-dimensional structure 300-1 at a temperature of about 50 ° C. for 30 minutes to 1 hour, and then at a temperature of about 80 ° C. Heat treatment is performed for 30 minutes to 1 hour.
- the urethane resin impregnation apparatus 150 of FIG. 1 applies to the three-dimensional structure 300-2 subjected to the first heat treatment in step S7 according to the control of the information processing / control apparatus 120.
- a treatment for impregnating the urethane resin is performed.
- the impregnation method by the urethane resin impregnation apparatus 150 for example, a form in which the urethane resin is impregnated using a brush, a form in which the urethane resin is sprayed and impregnated, or a container filled with the urethane resin is 3 It is possible to adopt a form in which the three-dimensional structure 300-2 is immersed and impregnated.
- the urethane resin used in the urethane resin impregnation apparatus 150 is not particularly limited as long as it can be cured with a liquid urethane resin, but the operation is simplified by using a one-component moisture-curing urethane resin. This is preferable.
- a urethane resin obtained by diluting a mixture of a polyol and a polyisocyanate with butyl acetate, ethyl acetate, or the like is used as a material of the urethane resin used in the urethane resin impregnation apparatus 150.
- the second heat treatment apparatus 160 of FIG. 1 predetermines the three-dimensional structure 300-3 that has been impregnated with the urethane resin in step S8 in accordance with the control of the information processing / control apparatus 120.
- Heat treatment (second heat treatment) is performed at a temperature of.
- the second heat treatment apparatus 160 first heat-treats the three-dimensional structure 300-3 at a temperature of 15 ° C. or more for 12 to 24 hours, and then performs a temperature of 80 ° C. Heat treatment is performed for about 2 hours.
- the aqueous medium immersion device 170 of FIG. 1 converts the three-dimensional structure 300-4 subjected to the second heat treatment in step S9 into the aqueous medium according to the control of the information processing / control device 120.
- the treatment is immersed in
- the three-dimensional structure manufacturing apparatus 100 performs a process of taking out the three-dimensional structure 300-5 from the aqueous medium immersion device 170.
- any one of the first heat treatment in step S7 in FIG. 2 and the second heat treatment in step S9 in FIG. A mode in which one or both are omitted is also applicable to this embodiment.
- the process of the flowchart shown in FIG. 2 is finished.
- the three-dimensional structure 300 formed by including the gypsum and the urethane resin (and further including the antiseptic / antifungal agent) is manufactured by the powder lamination method.
- FIG. 4 shows a first embodiment of the present invention, and a three-dimensional structure 300-5 (aqueous) manufactured by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material 200 shown in FIG. It is a characteristic view which shows the result of the tensile strength test after a medium immersion).
- FIG. 4 shows each three-dimensional structure 300-5 immersed in an aqueous medium for one to two weeks in the aqueous medium immersion apparatus 170 of FIG. 1 (three-dimensional structure 300- of FIG. 5 described later).
- 5 (after immersion in an aqueous medium)) is a characteristic diagram showing the results of a tensile strength test.
- FIG. 4 shows each three-dimensional structure 300-5 immersed in an aqueous medium for one to two weeks in the aqueous medium immersion apparatus 170 of FIG. 1 (three-dimensional structure 300- of FIG. 5 described later).
- 5 (after immersion in an aqueous medium)) is a characteristic diagram showing the results of a tens
- FIG. 4 shows the results of a tensile strength test until each three-dimensional structure 300-5 is broken. That is, the end (upper right corner) of each graph shown in FIG. 4 indicates that each test piece was broken by the load.
- FIG. 4 shows the results of a tensile strength test with the distance between marked lines of each test piece set to 50 mm.
- FIG. 4 shows the results obtained by using an “AutoGraph AG-IS 50 kN” tensile strength tester manufactured by Shimadzu Corporation.
- the three-dimensional structure 300-5 in which the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is 10%, 20%, 30%, and 40% It was found that the tensile strength was higher than that of a three-dimensional structure in which the weight ratio of the urethane resin powder to the total weight was 0% (that is, the urethane resin powder was not mixed as the modeling material 200).
- the weight ratio of the urethane resin powder contained in the modeling material 200 to the total weight of the modeling material 200 is in the range of 5% to 60%. In this regard, FIG.
- the three-dimensional structure 300-5 in which the weight ratio of the urethane resin powder to 5% is 0% of the weight ratio of the urethane resin powder to the total weight of the modeling material 200 (that is, the urethane resin powder is not mixed as the modeling material 200). It has been found that the tensile strength is higher than that of a three-dimensional structure.
- the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is in the range of 20% to 40%.
- the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is in the range of 20% to 40%.
- FIG. 5 shows a first embodiment of the present invention, and a three-dimensional structure 300-2 (urethane produced by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material 200 shown in FIG.
- FIG. 6 is a characteristic diagram showing the results of rubber hardness tests of a three-dimensional structure 300-3 (after urethane resin impregnation) and a three-dimensional structure 300-5 (after immersion in an aqueous medium) before resin impregnation.
- the three-dimensional structure 300-5 (after immersion in an aqueous medium) in FIG. 5 is immersed in the aqueous medium for one to two weeks in the aqueous medium immersion apparatus 170 in FIG.
- FIG. 5 shows the results obtained using a durometer type A rubber hardness tester.
- each of the three-dimensional shaped objects 300-5 (after immersion in an aqueous medium) is immersed in the aqueous medium, thereby each of the three-dimensional structure 300-2 before being immersed in the aqueous medium. It was found to be significantly softer than (before urethane resin impregnation) and the three-dimensional structure 300-3 (after urethane resin impregnation). Further, from the results of the rubber hardness test shown in FIG. 5, each of the three-dimensional shaped objects 300-5 (after immersion in an aqueous medium) is 3% in which the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is 0%.
- the three-dimensional structure 300-3 (after impregnation with the urethane resin) in which the weight ratio of the urethane resin powder to the total weight of the modeling material 200 is 5%, 20%, and 30% is It was found that the impregnation with the urethane resin is slightly softer than the three-dimensional structure 300-2 (before the impregnation with the urethane resin) before impregnation with the urethane resin.
- FIG. 6 shows the first embodiment of the present invention, and the underwater of the three-dimensional structure 300-5 manufactured by changing the weight ratio (%) of the urethane resin powder to the total weight of the modeling material 200 shown in FIG. It is a figure which shows the propriety of the shape maintenance in storage.
- the three-dimensional structure 300-5 that can retain the shape during underwater storage is indicated by “ ⁇ ”
- the three-dimensional structure 300-5 that cannot retain the shape during underwater storage is indicated by “ ⁇ ”.
- setting the upper limit of the weight ratio of the urethane resin powder to the total weight of the modeling material 200 to be 60% indicates that the three-dimensional model 300, which is a finished product when stored in an aqueous medium, from the results shown in FIG. From the standpoint of maintaining the shape of
- a three-dimensional structure 300 is formed by a powder lamination method using a modeling material in which urethane resin powder is mixed with gypsum powder. Since the urethane resin is impregnated, as described with reference to FIG. 4, the strength is higher than that of the three-dimensional structure formed using the modeling material in which the urethane resin powder is not mixed with the gypsum powder (0%). A three-dimensional structure can be formed. In addition, as described with reference to FIG. 5, by impregnating the urethane resin, the three-dimensional structure 300 before being impregnated with the urethane resin can be slightly softened.
- the three-dimensional structure 300 is immersed in the aqueous medium, so that it is softer as described with reference to FIG.
- a three-dimensional structure can be formed.
- the technique of this embodiment is applied to the medical field, it is possible to form a three-dimensional structure that reproduces an individual patient's organ in a form that is closer to the real object. It is possible to improve the quality of medical care.
- FIG. 7 is a block diagram showing an example of a schematic configuration of a three-dimensional structure manufacturing apparatus 400 according to the second embodiment of the present invention.
- the same reference numerals are given to the same configurations as the schematic configuration of the three-dimensional structure manufacturing apparatus 100 according to the first embodiment shown in FIG. 1, and the detailed description thereof is omitted.
- the three-dimensional structure manufacturing apparatus 400 includes an information input device 110, an information processing / control device 120, a three-dimensional structure formation apparatus 130, a first heat treatment apparatus 140, and urethane.
- the apparatus includes a resin impregnation apparatus 150, a second heat treatment apparatus 160, a soft resin forming apparatus 410, a third heat treatment apparatus 420, and an aqueous medium immersion apparatus 430.
- the information input device 110, the information processing / control device 120, the three-dimensional structure forming device 130, the first heat treatment device 140, the urethane resin impregnation device 150, and the second heat treatment device 160 are shown in FIG. Since it is the same as that of each structure in the manufacturing apparatus 100 of the three-dimensional structure based on 1 embodiment, the description is abbreviate
- the soft resin forming apparatus 410 is an apparatus that forms soft resin softer than the three-dimensional structure in the hollow area of the three-dimensional structure 300-4 according to the control of the information processing / control device 120.
- the soft resin 500 used in the soft resin forming apparatus 410 is formed using a urethane resin in which a polyisocyanate compound or the like is mixed with a polyol compound as a main material.
- the soft resin 500 in this embodiment includes a main component of a polyol compound and a curing agent such as a polyisocyanate compound (for example, a curing agent including polyisocyanate, diisononyl phthalate (DINP) and hexamethylene diisocyanate). And a two-component mixed urethane resin as a main material.
- the polyisocyanate preferably has a weight ratio in the range of 10% to 20% with respect to the total weight of the curing agent, and diisononyl phthalate is the total of the curing agent.
- the weight ratio with respect to the weight is preferably in the range of 80% to 90%, and the weight ratio of hexamethylene diisocyanate with respect to the total weight of the curing agent and the like is preferably 0.15% or less.
- the soft resin 500 is an ultrasonic scattering material for projecting the soft resin formed in the hollow region of the three-dimensional structure 300 in ultrasonic imaging. It shall be formed including.
- urethane resin powder is used as the ultrasonic scattering material.
- the present invention is not limited to this.
- carbon powder or gypsum powder is used.
- a pigment may be mixed with the soft resin 500 in the present embodiment so that various colors can be applied to the soft resin formed on the three-dimensional structure 300.
- the ultrasonic scattering material contained in the soft resin 500 is a two-component mixed urethane contained in the soft resin 500 from the viewpoint of projecting the soft resin formed in the hollow region of the three-dimensional structure 300 in ultrasonic imaging.
- the weight ratio with respect to the total weight of the resin is preferably in the range of 10% to 25%. This is because, when the weight ratio of the ultrasonic scattering material to the total weight of the two-component mixed urethane resin contained in the soft resin 500 is less than 10% or more than 25%, three-dimensional modeling is performed in ultrasonic imaging. This is because it becomes difficult to project the soft resin formed in the hollow region of the object 300.
- the third heat treatment apparatus 420 heat-treats the three-dimensional structure 300-6 on which the soft resin sr is formed in the soft resin forming apparatus 410 at a predetermined temperature according to the control of the information processing / control apparatus 120 (third heat treatment). It is a device to do.
- the third heat treatment apparatus 420 performs heat treatment on the three-dimensional structure 300-6 at a temperature of about 60 ° C. for about 3 hours.
- the soft resin sr in the three-dimensional structure 300-6 is cured by the third heat treatment by the third heat treatment apparatus 420.
- the aqueous medium immersion apparatus 430 is an apparatus for immersing the three-dimensional structure 300-7 heat-treated by the third heat treatment apparatus 420 in the aqueous medium under the control of the information processing / control apparatus 120.
- the aqueous medium is not particularly limited as long as the strength and softness of the three-dimensional structure 300 are not impaired, but water, physiological saline, buffer solution, aqueous organic solvent such as glycerin and ethylene glycol, or A mixture of these can be mentioned, and a water-soluble substance can also be dissolved in them.
- an antiseptic / antifungal agent can be added to the aqueous medium described above.
- the antiseptic / antifungal agent has a preservative / antifungal function for the three-dimensional structure 300-7 and an aqueous medium, and does not affect the strength and softness of the three-dimensional structure 300.
- an antifungal agent in consideration of handling, surgical training, etc., those with low irritation are preferable, such as hydrogen peroxide, hypochlorous acid, sodium hypochlorite, phenoxyethanol, benzoic acid Examples thereof include sodium acid, paraoxybenzoic acid ester, and salts thereof, and can be used at appropriate concentrations that exhibit antiseptic and antifungal functions, respectively.
- the aqueous medium immersion device 430 for example, immerses the three-dimensional structure 300-7 in an aqueous medium having a temperature of 80 ° C. to 95 ° C. for about 1 hour.
- the three-dimensional structure manufacturing apparatus 400 performs a process of taking out the three-dimensional structure 300-8 from the aqueous medium immersion device 430.
- FIG. 7 an embodiment in which three heat treatment apparatuses, the first heat treatment apparatus 140, the second heat treatment apparatus 160, and the third heat treatment apparatus 420 are provided, is shown in the present embodiment.
- one heat treatment apparatus is provided, and the first heat treatment by the first heat treatment apparatus 140, the second heat treatment by the second heat treatment apparatus 160, and the first heat treatment apparatus are provided in one heat treatment apparatus.
- a mode in which the third heat treatment by the third heat treatment apparatus 420 is also applicable to this embodiment.
- at least one of the first heat treatment apparatus 140, the second heat treatment apparatus 160, and the third heat treatment apparatus 420, or its A mode in which not all are provided is also applicable to this embodiment.
- the soft resin sr in the three-dimensional structure 300-6 is reacted for a long time without providing the third heat treatment apparatus 420, a reaction of about 24 hours is required at room temperature.
- FIG. 8 is a flowchart showing an example of a processing procedure in the method for manufacturing a three-dimensional structure executed by the three-dimensional structure manufacturing apparatus 400 according to the second embodiment of the present invention.
- the processing of the flowchart shown in FIG. 8 will be described below with reference to FIG.
- the same step numbers are assigned to the same processing steps as the processing of the flowchart in the first embodiment shown in FIG. 2, and detailed description thereof is omitted.
- the soft resin forming apparatus 410 of FIG. 7 is softer than the three-dimensional structure in the hollow region of the three-dimensional structure 300-4 according to the control of the information processing / control apparatus 120.
- a process of forming a resin is performed.
- the soft resin 500 used in the soft resin forming apparatus 410 includes, as a main material, a urethane resin that is a two-component mixture of a main component of a polyol compound and a curing agent such as a polyisocyanate compound.
- an ultrasonic scattering material for projecting the soft resin formed in the hollow region of the three-dimensional structure 300 in ultrasonic imaging is included.
- the third heat treatment apparatus 420 of FIG. 7 performs the three-dimensional structure 300- in which the soft resin sr is formed in the soft resin forming apparatus 410 according to the control of the information processing / control apparatus 120. 6 is heat-treated at a predetermined temperature (third heat treatment).
- the third heat treatment apparatus 420 performs heat treatment on the three-dimensional structure 300-6 at a temperature of about 60 ° C. for about 3 hours.
- the aqueous medium immersion device 430 of FIG. 7 converts the three-dimensional structure 300-7 heat-treated by the third heat treatment device 420 according to the control of the information processing / control device 120 to the aqueous medium.
- the treatment is immersed in
- the three-dimensional structure manufacturing apparatus 400 performs a process of taking out the three-dimensional structure 300-8 from the aqueous medium immersion device 430.
- a mode in which at least one or all of the third heat treatments in step S22 are omitted is also applicable to this embodiment.
- the soft resin sr in the three-dimensional structure 300-6 is reacted over a long period of time without performing the third heat treatment in step S22 of FIG. 8, a reaction of about 24 hours is required at room temperature.
- a three-dimensional structure 300 including gypsum and urethane resin (further including an antiseptic / antifungal agent) and a soft resin sr is manufactured by a powder lamination method. Is done.
- the ultrasonic imaging described below was performed using an ultrasonic diagnostic apparatus “LogiQ-S8” manufactured by GE Healthcare, with a frequency Fq of 8 MHz and a frame rate FR of 36 at the time of imaging. Is.
- FIG. 9A is a diagram illustrating a three-dimensional structure 300 obtained by ultrasonic imaging. Specifically, FIG. 9A shows three-dimensional structure divided pieces 300a and 300b obtained by dividing a three-dimensional structure 300 obtained by ultrasonic imaging into two. FIG. 9B shows a comparative example of a three-dimensional structure 300 manufactured without forming a hollow region (that is, without forming a soft resin, and using a modeling material in which all soft resin portions are mixed with powder). It is an external view.
- FIG. 9C shows a comparative example, and the three-dimensional structure 300 of FIG. 9B manufactured without forming a hollow region (that is, with a modeling material in which all of the soft resin is mixed with powder without forming a soft resin). It is a figure which shows the result of having carried out ultrasonic imaging
- the inside of the three-dimensional structure 300 cannot be projected in ultrasonic imaging.
- the inside of the three-dimensional structure 300 obtained as a result shown in FIG. 9C is a modeling material in which a hollow region is not formed (that is, a soft resin portion is not formed and all soft resin portions are mixed with powder).
- the ultrasonic wave is absorbed in the vicinity of the surface of the three-dimensional structure 300 and is not propagated to the inside, so that only the contour is displayed.
- FIG. 9D is a diagram showing a result of ultrasonic imaging of the three-dimensional structure 300 of FIG. 9A in which the soft resin sr is formed in the hollow region according to the second embodiment of the present invention.
- the region where the soft resin sr is formed in the three-dimensional structure 300 can be projected in ultrasonic imaging. This is considered to be obtained as a result of including the above-described ultrasonic scattering material in the soft resin 500.
- the three-dimensional structure that produced the ultrasonic imaging result of FIG. 9C was manufactured only with the modeling material mixed with the powder, and the ultrasonic wave did not propagate to the inside, whereas the ultrasonic imaging result of FIG. 9D. Since the three-dimensional structure provided with the hollow region is provided inside, the thickness of the surface portion made of the molding material mixed with the powder is thin, and the ultrasonic wave reaches the soft resin sr formed in the hollow region.
- the vertical black belt-like region near the center in FIG. 9D corresponds to the upper portion of the black belt and is formed in the outer shell portion of the hollow region made of the modeling material mixed with the powder and the hollow region below the hollow region. Since air entered during the ultrasonic imaging between the formed soft resin and ultrasonic waves did not propagate to the soft resin, the soft resin containing the ultrasonic scattering material could not be projected and was black. This is a band-like region. If air does not enter, the ultrasonic wave propagates through the soft resin and the part where the ultrasonic wave is scattered appears in white just like the left and right sides of the black belt-like region. It has no effect.
- the soft resin sr that is softer than the three-dimensional structure is formed in the hollow region of the three-dimensional structure 300, in addition to the effects of the first embodiment.
- the three-dimensional structure 300 having portions with different softness can be formed.
- the soft resin includes an ultrasonic scattering material for projecting the soft resin formed in the hollow region of the three-dimensional structure 300 in ultrasonic imaging. Therefore, it is possible to form the three-dimensional structure 300 that can be imaged by the ultrasonic diagnostic apparatus.
- the technique of the present embodiment is applied to the medical field, for example, by reproducing a lesion portion with a soft resin sr, it is possible to form a three-dimensional structure that reproduces an individual patient's organ in a form closer to the real thing. Therefore, for example, the three-dimensional structure can be used for general surgical training, surgical training using an ultrasonic diagnostic apparatus, and the like, and it is possible to improve medical quality.
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Abstract
Description
本発明の3次元造形物の製造方法における他の態様は、前記ウレタン樹脂を含浸させる工程が終了した後、前記3次元造形物を水性媒体に浸漬する工程を更に有する。
また、本発明の3次元造形物の製造方法におけるその他の態様は、前記水性媒体には、防腐・防カビ剤が溶解されている。
また、本発明の3次元造形物の製造方法におけるその他の態様は、前記ウレタン樹脂を含浸させる工程が終了した後であって前記水性媒体に浸漬する工程の前に、前記3次元造形物の中空領域に当該3次元造形物よりも柔らかい軟質樹脂を形成する工程を更に有する。
また、本発明の3次元造形物の製造方法におけるその他の態様は、前記軟質樹脂は、ウレタン樹脂を主材料として形成されている。
また、本発明の3次元造形物の製造方法におけるその他の態様は、前記軟質樹脂は、前記主材料に加えて、超音波撮影において前記中空領域に形成された当該軟質樹脂を映出させるための超音波散乱材料を含み形成されている。
また、本発明の3次元造形物の製造方法におけるその他の態様は、前記ウレタン樹脂粉末は、前記造形材料の総重量に対する重量比率が5%~60%である。
また、本発明は、上述した3次元造形物の製造方法を実行する3次元造形物の製造装置、上述した3次元造形物の製造方法により製造された3次元造形物、及び、上述した3次元造形物の製造方法で用いる造形材料を含む。
まず、本発明の第1の実施形態に係る3次元造形物の製造装置の概略構成について説明する。
本実施形態における造形材料200は、上述したように、石膏粉末にウレタン樹脂粉末及び防腐・防カビ剤が混合されている。具体的に、本実施形態では、造形材料200に含まれる防腐・防カビ剤として、銀含有非晶質ガラス粉末を用いる。
造形材料200に含まれるウレタン樹脂粉末は、造形材料200の総重量に対する重量比率が5%~60%の範囲であることが好適である。これは、造形材料200の総重量に対するウレタン樹脂粉末の重量比率が5%未満になると、石膏が支配的になって完成品である3次元造形物300が強度不足で脆くなるという不具合が生じ、また、造形材料200の総重量に対するウレタン樹脂粉末の重量比率が60%を超えると、完成品である3次元造形物300を保管(水性媒体中の保管)する際にその3次元造形物300の形状が保てず崩れてしまうという不具合が生じるためである。さらに、完成品である3次元造形物300の強度を高くするという観点からは、造形材料200の総重量に対するウレタン樹脂粉末の重量比率が20%~40%の範囲であることが最適である。また、造形材料200に含まれる防腐・防カビ剤は、造形材料200の総重量に対する重量比率が0.1%~5%の範囲であることが好適である。これは、造形材料200の総重量に対する防腐・防カビ剤の重量比率が0.1%未満になると、完成品である3次元造形物300の防腐・防カビ機能が不十分になるという不具合が生じるためである。また、造形材料200に含まれる石膏粉末は、造形材料200の総重量に対する重量比率が35%~94.9%の範囲であることが好適である。
全ての層のスライスデータにおける処理が完了すると、図2のステップS7に進む。
図2のステップS7に進むと、図1の第1の熱処理装置140は、情報処理・制御装置120の制御に従って、3次元造形物形成装置130で形成された3次元造形物300-1を所定の温度で熱処理(第1の熱処理)を行う。本実施形態においては、第1の熱処理装置140は、3次元造形物300-1に対して、最初に、温度50℃程度で30分~1時間の熱処理を行い、次いで、温度80℃程度で30分~1時間の熱処理を行う。
次に、本発明の第2の実施形態に係る3次元造形物の製造装置の概略構成について説明する。
本実施形態における軟質樹脂500は、ポリオール化合物にポリイソシアネート化合物などを混合したウレタン樹脂を主材料として形成されている。具体的に、本実施形態における軟質樹脂500は、ポリオール化合物の主剤と、ポリイソシアネート化合物などの硬化剤等(例えば、ポリイソシアネート、ジイソノニールフタレート(DINP)及びヘキサメチレンジイソシアネートを含む硬化剤等)との2液混合のウレタン樹脂を主材料として含み形成されている。この際、上述した硬化剤等において、ポリイソシアネートは当該硬化剤等の総重量に対する重量比率が10%~20%の範囲であることが好適であり、ジイソノニールフタレートは当該硬化剤等の総重量に対する重量比率が80%~90%の範囲であることが好適であり、ヘキサメチレンジイソシアネートは当該硬化剤等の総重量に対する重量比率が0.15%以下であることが好適である。さらに、本実施形態においては、軟質樹脂500は、上述した主材料に加えて、超音波撮影において3次元造形物300の中空領域に形成された当該軟質樹脂を映出させるための超音波散乱材料を含み形成されているものとする。この際、本実施形態においては、超音波散乱材料として、ウレタン樹脂粉末を用いるものとするが、本発明においてはこれに限定されるものではなく、例えば、カーボン粉末や石膏粉末を用いるようにしてもよい。さらに、本実施形態における軟質樹脂500に顔料を混ぜて、3次元造形物300に形成される軟質樹脂に各種の色を付けることができるようにしてもよい。
また、図9Bは、比較例を示し、中空領域を形成せずに(即ち軟質樹脂を形成せずに軟質樹脂の部分も全て粉末を混合させた造形材料で)製造した3次元造形物300の外観図である。
Claims (20)
- 石膏粉末にウレタン樹脂粉末を混合させた造形材料を用いて、粉体積層法により3次元造形物を形成する工程と、
前記3次元造形物に対してウレタン樹脂を含浸させる工程と
を有することを特徴とする3次元造形物の製造方法。 - 前記ウレタン樹脂を含浸させる工程が終了した後、前記3次元造形物を水性媒体に浸漬する工程を更に有することを特徴とする請求項1に記載の3次元造形物の製造方法。
- 前記水性媒体には、防腐・防カビ剤が溶解されていることを特徴とする請求項2に記載の3次元造形物の製造方法。
- 前記ウレタン樹脂を含浸させる工程が終了した後であって前記水性媒体に浸漬する工程の前に、前記3次元造形物の中空領域に当該3次元造形物よりも柔らかい軟質樹脂を形成する工程を更に有することを特徴とする請求項2または3に記載の3次元造形物の製造方法。
- 前記軟質樹脂は、ウレタン樹脂を主材料として形成されていることを特徴とする請求項4に記載の3次元造形物の製造方法。
- 前記軟質樹脂は、前記主材料に加えて、超音波撮影において前記中空領域に形成された当該軟質樹脂を映出させるための超音波散乱材料を含み形成されていることを特徴とする請求項5に記載の3次元造形物の製造方法。
- 前記ウレタン樹脂粉末は、前記造形材料の総重量に対する重量比率が5%~60%であることを特徴とする請求項1乃至6のいずれか1項に記載の3次元造形物の製造方法。
- 石膏粉末にウレタン樹脂粉末を混合させた造形材料を用いて、粉体積層法により3次元造形物を形成する3次元造形物形成手段と、
前記3次元造形物に対してウレタン樹脂を含浸させるウレタン樹脂含浸手段と
を有することを特徴とする3次元造形物の製造装置。 - 前記ウレタン樹脂含浸手段による前記ウレタン樹脂の含浸が終了した後、前記3次元造形物を水性媒体に浸漬する水性媒体浸漬手段を更に有することを特徴とする請求項8に記載の3次元造形物の製造装置。
- 前記水性媒体には、防腐・防カビ剤が溶解されていることを特徴とする請求項9に記載の3次元造形物の製造装置。
- 前記ウレタン樹脂含浸手段による前記ウレタン樹脂の含浸が終了した後であって前記水性媒体浸漬手段による前記水性媒体に浸漬する前に、前記3次元造形物の中空領域に当該3次元造形物よりも柔らかい軟質樹脂を形成する軟質樹脂形成手段を更に有することを特徴とする請求項9または10に記載の3次元造形物の製造装置。
- 前記軟質樹脂は、ウレタン樹脂を主材料として形成されていることを特徴とする請求項11に記載の3次元造形物の製造装置。
- 前記軟質樹脂は、前記主材料に加えて、超音波撮影において前記中空領域に形成された当該軟質樹脂を映出させるための超音波散乱材料を含み形成されていることを特徴とする請求項12に記載の3次元造形物の製造装置。
- 前記ウレタン樹脂粉末は、前記造形材料の総重量に対する重量比率が5%~60%であることを特徴とする請求項8乃至13のいずれか1項に記載の3次元造形物の製造装置。
- 粉体積層法により石膏とウレタン樹脂とを含み形成されていることを特徴とする3次元造形物。
- 前記粉体積層法により石膏とウレタン樹脂とを含み形成されてなる3次元造形物の中空領域に当該3次元造形物よりも柔らかい軟質樹脂が形成されていることを特徴とする請求項15に記載の3次元造形物。
- 前記軟質樹脂は、ウレタン樹脂を主材料として形成されていることを特徴とする請求項16に記載の3次元造形物。
- 前記軟質樹脂は、前記主材料に加えて、超音波撮影において前記中空領域に形成された当該軟質樹脂を映出させるための超音波散乱材料を含み形成されていることを特徴とする請求項17に記載の3次元造形物。
- 粉体積層法により3次元造形物を形成する際に用いる造形材料であって、
石膏粉末にウレタン樹脂粉末を混合させたことを特徴とする造形材料。 - 前記ウレタン樹脂粉末は、当該造形材料の総重量に対する重量比率が5%~60%であることを特徴とする請求項19に記載の造形材料。
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JP2020175510A (ja) * | 2019-04-15 | 2020-10-29 | 丸越工業株式会社 | 珪藻土入り造形用材料及び珪藻土製品の製造方法 |
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