阅读说明：本技术 三维造型物的造型方法 (Method for molding three-dimensional object ) 是由 姊川贤太 青柳大蔵 于 2020-02-24 设计创作，主要内容包括：本申请公开了一种三维造型物的造型方法,提高通过造型材料的层叠和切削加工而作成的三维造型物的形状的自由度。使用在预定的切削方向上最大能够切削第一长度的切削工具的三维造型物的造型方法具有：第一部分造型工序,通过层叠造型材料,对沿着第一方向的长度短于第一长度的第一部分进行造型；第一部分切削工序,利用使切削方向沿着第一方向的切削工具,切削第一部分；第二部分造型工序,通过层叠造型材料,对第二部分进行造型,第二部分连接于第一部分的第一方向的第一端面,第二部分的沿着第二方向的长度短于第一长度；以及第二部分切削工序,利用使切削方向沿着第二方向的切削工具,沿着第二方向切削第二部分。(Disclosed is a method for forming a three-dimensional shaped object, which improves the degree of freedom in the shape of the three-dimensional shaped object formed by laminating molding materials and cutting. A three-dimensional shaped object forming method using a cutting tool capable of cutting a first length at maximum in a predetermined cutting direction includes: a first part molding step of molding a first part having a length in the first direction shorter than a first length by laminating molding materials; a first partial cutting step of cutting a first part with a cutting tool having a cutting direction along a first direction; a second part molding step of molding a second part by laminating molding materials, the second part being connected to a first end surface of the first part in the first direction, the second part having a length in the second direction shorter than the first length; and a second partial cutting step of cutting a second part in the second direction by using a cutting tool having a cutting direction in the second direction.)

1. A method of forming a three-dimensional object using a cutting tool capable of cutting a maximum first length in a predetermined cutting direction, the method comprising:

a first part molding step of molding a first part having a length in a first direction shorter than the first length by laminating molding materials;

a first partial cutting step of cutting the first part with the cutting tool having the cutting direction along the first direction;

a second part molding step of molding a second part by laminating the molding material, the second part being connected to a first end surface of the first part in the first direction, a length of the second part in the second direction being shorter than the first length; and

and a second partial cutting step of cutting the second portion in the second direction by using the cutting tool having the cutting direction along the second direction.

2. The method of molding a three-dimensional shaped object according to claim 1,

the first direction and the second direction are the same direction.

3. The method of molding a three-dimensional shaped object according to claim 1,

the first direction and the second direction are different directions.

4. The method of three-dimensionally shaping an object according to any one of claims 1 to 3,

at least either one of a length of adding the first portion and the second portion together in the first direction and a length of adding the first portion and the second portion together in the second direction is longer than the first length.

5. The method of molding a three-dimensional shaped object according to claim 1,

an inclination angle of the first end face in the first portion with respect to a table on which the modeling material is stacked is smaller than an inclination angle of a side face in a nozzle that ejects the modeling material with respect to the table.

6. The method of molding a three-dimensional shaped object according to claim 1,

the method includes a heating step of heating the first end surface of the first part before the second part molding step.

7. The method of molding a three-dimensional shaped object according to claim 1,

the first portion has a raised portion shaped to contact a table and configured to secure a distance between a cutting allowance of the first portion cut in the first portion cutting process and the table.

Technical Field

The present invention relates to a method for molding a three-dimensional object.

Background

For example, patent document 1 discloses a method of manufacturing a metal powder sintered part in which a plurality of sintered layers are laminated by irradiating a metal powder layer with laser light to perform sintering. In this method, after the sintered layer is formed to be larger than a desired shape by a predetermined size, unnecessary portions are removed by cutting.

Patent document 1: japanese patent laid-open publication No. 2003-313604

Disclosure of Invention

In the case where a three-dimensional object is formed by removing unnecessary portions from a layer formed by cutting as in the above-described method, a cutting tool may not reach the unnecessary portions and a three-dimensional object having a desired shape may not be formed. For example, when a tubular three-dimensional object having a length longer than the cutting tool can cut is formed, the cutting tool cannot reach the inner circumferential surface of the tube, and a three-dimensional object having a desired shape cannot be formed. Therefore, an object of the present invention is to improve the degree of freedom of the shape of a three-dimensional shaped object formed by laminating molding materials and cutting.

According to an aspect of the present invention, there is provided a method of forming a three-dimensional shaped object using a cutting tool capable of cutting a first length at maximum in a predetermined cutting direction. The method for molding the three-dimensional molded object comprises the following steps: a first part molding step of molding a first part having a length in a first direction shorter than the first length by laminating molding materials; a first partial cutting step of cutting the first part with the cutting tool having the cutting direction along the first direction; a second part molding step of molding a second part by laminating the molding material, the second part being connected to a first end surface of the first part in the first direction, a length of the second part in the second direction being shorter than the first length; and a second partial cutting step of cutting the second portion in the second direction by the cutting tool having the cutting direction in the second direction.

Drawings

Fig. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus in a first embodiment.

Fig. 2 is an explanatory diagram showing a schematic configuration of the ejection unit in the first embodiment.

Fig. 3 is a perspective view showing a configuration of a groove forming surface of the grub screw in the first embodiment.

Fig. 4 is a plan view showing a configuration of a screw facing surface of the cylinder in the first embodiment.

Fig. 5 is a flowchart showing the contents of the data generation processing in the first embodiment.

Fig. 6 is a perspective view showing a first shape in the first embodiment.

Fig. 7 is a perspective view showing a second shape in the first embodiment.

Fig. 8 is a perspective view showing a third shape in the first embodiment.

Fig. 9 is an explanatory diagram schematically showing the modeling path and the cutting path.

Fig. 10 is an explanatory diagram schematically showing modeling data and cutting data.

Fig. 11 is a flowchart showing the contents of the modeling process in the first embodiment.

Fig. 12 is a process diagram illustrating a first partial molding step in the first embodiment.

Fig. 13 is a cross-sectional view along line XIII-XIII showing the first part.

Fig. 14 is a process diagram illustrating a first partial cutting process in the first embodiment.

Fig. 15 is a process diagram illustrating a first heating step in the first embodiment.

Fig. 16 is a process diagram illustrating a second partial molding step in the first embodiment.

Fig. 17 is a process diagram illustrating a second partial cutting process in the first embodiment.

Fig. 18 is a process diagram illustrating a second heating step in the first embodiment.

Fig. 19 is a process diagram showing a third partial molding step in the first embodiment.

Fig. 20 is a process diagram illustrating a third partial cutting step in the first embodiment.

Fig. 21 is a first explanatory view showing another embodiment of a three-dimensional shaped object.

Fig. 22 is a second explanatory view showing another embodiment of the three-dimensional shaped object.

Fig. 23 is an explanatory diagram showing a schematic configuration of an ejection unit as another embodiment.

Description of the reference numerals

10 … three-dimensional modeling apparatus; 15 … information processing means; 16 … a data generating section; 20 … material supply; 22 … supply path; 30. 30b … fusion zone; 31 … screw housing; 32 … drive motor; 40 … grub screws; 41 … upper surface; 42 … groove forming faces; 43 … side; 45 … groove portions; 46 … center portion; 47 … scroll; 48 … material introduction part; 50. barrel 50b …; 52. 52b … screw facing surface; 54 … guide slot; 56 … communicating with the aperture; 58. 58b … heater; 60 … ejection unit; a 61 … nozzle; 62 … nozzle hole; 65 … nozzle flow path; 70 … reheat section; 100. 100b … ejection unit; 140 … inline screws; 145 … groove portions; 200 … cutting unit; 210 … cutting tool; 300 … a workbench; 310 … molding surface; 400 … moving mechanism; 500 … control section; 810 … a bend; 820 … straight line portion; 825 … inner wall surface; 901 … sculpting portion; 902 … a body portion; 903 … cutting part; 904 … a support portion; 905 … elevated portion; 910. 910b, 910c …; 911 … first end face; 920. 920b, 920c … second portion; 921 … second end face; 930. 930b, 930c ….

Detailed Description

A. The first embodiment:

fig. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus 10 in a first embodiment. In fig. 1, arrows along mutually orthogonal directions X, Y, Z are shown. The X-direction and the Y-direction are directions along the horizontal direction, and the Z-direction is a direction along the vertical direction. In the other figures, arrows along the direction X, Y, Z are shown as appropriate. The X, Y, Z orientation in fig. 1 and the X, Y, Z orientation in the other figures represent the same orientation.

The three-dimensional modeling apparatus 10 in the present embodiment includes a discharge unit 100, a cutting unit 200, a table 300, a moving mechanism 400, and a control unit 500. The information processing device 15 is connected to the control section 500. The three-dimensional modeling apparatus 10 and the information processing apparatus 15 may be combined and interpreted as a three-dimensional modeling apparatus in a broad sense.

The three-dimensional modeling apparatus 10 stacks the modeling material on the table 300 by driving the moving mechanism 400 while ejecting the modeling material from the nozzle 61 provided in the ejection unit 100 toward the modeling surface 310 of the table 300 and changing the relative position between the nozzle 61 and the table 300 under the control of the control section 500. In addition, the detailed configuration of the ejection unit 100 will be described later with reference to fig. 2.

Further, the three-dimensional modeling apparatus 10 of the present embodiment cuts the modeling material stacked on the table 300 by driving the moving mechanism 400 while rotating the cutting tool 210 attached to the cutting unit 200 and changing the relative position between the cutting tool 210 and the table 300 under the control of the control unit 500. Thus, the three-dimensional modeling apparatus 10 creates a three-dimensional object OB having a desired shape. Fig. 1 schematically shows a three-dimensional object OB.

The cutting unit 200 is a cutting device that rotates a cutting tool 210 attached to a shaft at the front end of the head to cut the modeling material laminated on the table 300. As the cutting tool 210, for example, a flat end mill or a round end mill can be used. The cutting unit 200 detects the position of the tip of the cutting tool 210 using a general position detection sensor, and transmits the detection result to the control unit 500. Using the detection result, the control unit 500 controls the relative positional relationship between the cutting tool 210 and the laminated molding material by the movement mechanism 400 described later, and performs cutting. The cutting unit 200 may include a ionizer and the like.

The moving mechanism 400 changes the relative positions of the ejection unit 100 and the cutting unit 200 and the table 300. In the present embodiment, the moving mechanism 400 moves the table 300 with respect to the ejection unit 100 and the cutting unit 200. The moving mechanism 400 in the present embodiment is constituted by a three-axis positioner that moves the table 300 in three axial directions in the direction X, Y, Z by the driving forces of three motors. Each motor is driven under the control of the control part 500. The moving mechanism 400 may move the discharge unit 100 and the cutting unit 200 without moving the table 300, instead of moving the table 300. The moving mechanism 400 may be configured to move both the discharge unit 100, the cutting unit 200, and the table 300.

The control unit 500 is constituted by a computer including one or more processors, a main storage device, and an input/output interface for inputting and outputting signals to and from the outside. In the present embodiment, the control unit 500 performs various functions by the processor executing programs and instructions read in the main storage device. The control unit 500 may be configured by a combination of a plurality of circuits instead of a computer.

The information processing device 15 is constituted by a computer including one or more processors, a main storage device, and an input/output interface for inputting and outputting signals to and from the outside. In the present embodiment, the information processing device 15 performs various functions by executing programs and instructions read in the main storage device by the processor. The information processing device 15 includes a data generation unit 16. As will be described later with reference to fig. 5 to 10, the data generation section 16 generates data for modeling and data for cutting, and the control section 500 for the three-dimensional modeling apparatus 10 controls the ejection unit 100 and the cutting unit 200 and the movement mechanism 400.

Fig. 2 is an explanatory diagram showing a schematic configuration of the ejection unit 100 in the present embodiment. The discharge unit 100 includes a material supply unit 20, a melting unit 30, a discharge unit 60, and a reheating unit 70. The material supply unit 20 is filled with a material in a state of particles, powder, or the like. The material in the present embodiment is a granular ABS resin. The material supply unit 20 in the present embodiment is constituted by a hopper. The material supplying portion 20 and the melting portion 30 are connected to each other through a supply path 22 provided below the material supplying portion 20. The material filled in the material supply portion 20 is supplied to the melting portion 30 via the supply path 22.

The melting section 30 includes a screw housing 31, a drive motor 32, a grub screw 40, and a cylinder 50. The melting section 30 melts at least a part of the material in a solid state supplied from the material supply section 20 to form a paste-like molding material having fluidity, and supplies it to the nozzle 61. In addition, the grub screw 40 may be simply referred to as a screw.

The screw housing 31 accommodates a grub screw 40. The driving motor 32 is fixed to an upper surface of the screw housing 31. The rotational axis of the drive motor 32 is connected to the upper surface 41 of the grub screw 40.

The grub screw 40 has a substantially cylindrical shape with a height in the direction of the central axis RX that is smaller than the diameter. The grub screw 40 is arranged in the screw housing 31 with the central axis RX parallel to the Z direction. The grub screw 40 is rotated about the central axis RX in the screw housing 31 by the torque generated by the drive motor 32.

The grub screw 40 has a groove forming surface 42 on the opposite side to the upper surface 41 in the direction along the central axis RX. The groove 45 is formed on the groove forming surface 42. The detailed shape of the groove forming surface 42 of the grub screw 40 will be described later with reference to fig. 6.

Barrel 50 is disposed below grub screw 40. The barrel 50 has a screw facing surface 52 facing the slot forming surface 42 of the grub screw 40. In the cylinder 50, the heater 58 is built in a position facing the groove 45 of the grub screw 40. The temperature of the heater 58 is controlled by the control section 500. In addition, the heater 58 may be referred to as a heating portion.

A communication hole 56 is provided in the center of the screw facing surface 52. The communication hole 56 communicates with the nozzle 61. In addition, the detailed shape of the screw facing surface 52 of the cylinder 50 will be described later with reference to fig. 6.

The discharge unit 60 includes a nozzle 61. The nozzle 61 is provided with a nozzle flow path 65 and a nozzle hole 62. The nozzle flow field 65 communicates with the communication hole 56 of the melting unit 30. The nozzle hole 62 is an opening portion that communicates with the nozzle flow path 65 and is provided at the tip end portion of the nozzle 61. The molding material supplied from the melting section 30 to the nozzle 61 is ejected from the nozzle hole 62. In the present embodiment, the nozzle 61 is provided with a circular nozzle hole 62. The diameter of the nozzle hole 62 is referred to as a nozzle diameter Dn. The nozzle 61 is arranged such that a side surface of a front end of the nozzle 61 forms an inclination angle θ n with respect to the stage 300. The shape of the nozzle hole 62 is not limited to a circle, and may be a square.

The reheating part 70 reheats the molding material, which is laminated on the work stage 300 and cured. In the present embodiment, the reheating section 70 is constituted by a heater disposed adjacent to the nozzle 61. The temperature of the reheating section 70 is controlled by the control section 500.

Fig. 3 is a perspective view showing a configuration of the groove forming surface 42 of the grub screw 40 in the present embodiment. For the purpose of easy understanding of the technique, the grub screw 40 shown in fig. 3 is shown in a state where the up-down positional relationship shown in fig. 2 is reversed. As described above, the groove portion 45 is formed on the groove forming surface 42 of the grub screw 40. The groove 45 has a central portion 46, a spiral portion 47, and a material introduction portion 48.

The central portion 46 is a circular depression formed about the central axis RX of the grub screw 40. The central portion 46 opposes a communication hole 56 provided in the cylinder 50.

The spiral portion 47 is a groove extending spirally with the center portion 46 as a center in an arc shape toward the outer periphery of the groove forming surface 42. The volute portion 47 may be configured to extend in an involute curve or in a spiral. One end of the volute 47 is connected to the central portion 46. The other end of the volute portion 47 is connected to the material introduction portion 48.

The material introducing portion 48 is a groove wider than the spiral portion 47 provided on the outer peripheral edge of the groove forming surface 42. The material lead-in 48 is connected to the side 43 of the grub screw 40. The material introducing portion 48 introduces the material supplied from the material supplying portion 20 through the supply path 22 into the volute portion 47. In addition, fig. 3 shows an embodiment in which one scroll portion 47 and one material introduction portion 48 are provided from the central portion 46 of the grub screw 40 toward the outer periphery, but a plurality of scroll portions 47 and a plurality of material introduction portions 48 may be provided from the central portion 46 of the grub screw 40 toward the outer periphery.

Fig. 4 is a plan view showing a structure of a screw facing surface 52 of a cylinder 50 in the present embodiment. As described above, the communication hole 56 communicating with the nozzle 61 is formed in the center of the screw facing surface 52. A plurality of guide grooves 54 are formed around the communication hole 56 in the screw facing surface 52. One end of each guide groove 54 is connected to the communication hole 56, and extends spirally from the communication hole 56 toward the outer periphery of the screw facing surface 52. Each guide groove 54 has a function of guiding the modeling material to the communication hole 56.

Fig. 5 is a flowchart showing the contents of the data generation processing in the present embodiment. When the user performs a predetermined start operation on the information processing device 15, the data generation unit 16 of the information processing device 15 performs the process. In the present embodiment, the modeling data and the cutting data are generated by this processing. The modeling data is data for controlling the ejection unit 100 and the movement mechanism 400, which are used to model the three-dimensional object OB by the three-dimensional modeling apparatus 10, in the ejection unit 100 and the movement mechanism 400. The cutting data is data for controlling the cutting unit 200 and the moving mechanism 400, and the cutting unit 200 and the moving mechanism 400 are used for cutting the three-dimensional shaped object OB by the three-dimensional shaping apparatus 10.

Fig. 6 is a perspective view showing the first shape SP1 indicated by the first shape data in the present embodiment. Referring to fig. 5 and 6, first, in step S110, the data generation unit 16 acquires first shape data indicating the first shape SP 1. The first shape SP1 is a shape representing a three-dimensional object OB created using three-dimensional CAD software or three-dimensional CG software. That is, the first shape SP1 can be said to be the design shape of the three-dimensional shaped object OB. As the first shape data, for example, STL-format, IGES-format, or STEP-format data may be used. The data generating unit 16 may acquire the first shape data created on the information processing device 15 using, for example, three-dimensional CAD software. The data generating unit 16 may acquire the first shape data created outside the information processing device 15 via a recording medium such as a USB memory. In the present embodiment, the first shape SP1 has a tubular shape. The first shape SP1 includes a bent portion 810 that is a portion where the tube is bent, and a linear portion 820 where the tube extends linearly. The first shape SP1 has an inner wall surface 825 on the tube inner side.

In step S120, the data generation unit 16 is provided at the position and direction where the three-dimensional shaped object OB indicated by the first shape SP1 is arranged on the table 300. For example, the data generation unit 16 sets the position and the direction in which the first shape SP1 is arranged on the table 300 according to the position and the direction designated by the user. In the present embodiment, the position and the direction of the first shape SP1 on the table 300 are set such that the center axis CL of the straight line portion 820 is parallel to the X direction.

Fig. 7 is a perspective view showing the second shape SP2 represented by the second shape data in the present embodiment. In fig. 7, the modeling surface 310 of the table 300 is indicated by a two-dot chain line as a reference. Referring to fig. 5 and 7, in step S130, the data generation unit 16 generates second shape data representing a second shape SP2 using the first shape data and information on the cutting process applied to the three-dimensional shaped object OB. The second shape SP2 is a shape of the three-dimensional shaped object OB to which the cutting portion 903, the supporting portion 904, and the raised portion 905 are added to the first shape SP 1. In addition, a portion included in the first shape SP1 and included in the second shape SP2 is referred to as a main body portion 902. The body portion 902 and the cutting portion 903 are collectively referred to as a shaping portion 901.

The cutting portion 903 is a cutting allowance for applying cutting work to the three-dimensional shaped object OB. For example, the data generating unit 16 arranges the cutting unit 903 in accordance with the position and size of the cutting work specified by the user. In the present embodiment, the cut portion 903 is provided on the inner wall surface 825.

The support portion 904 is a portion for maintaining the shape of the modeling portion 901 when modeling materials are laminated to model the three-dimensional modeled object OB. For example, the data generation unit 16 arranges the support portion 904 at a position designated by the user. When the three-dimensional object OB is molded based on the second shape SP2, the data generating unit 16 determines whether or not the shape of the three-dimensional object OB can be held, and if it is not determined that the shape of the three-dimensional object OB can be held, the data generating unit 16 may dispose the support portion 904. In this embodiment, the support portion 904 is configured so that the lower surface of the modeling portion 901 in the linear portion 820 can be supported. In addition, in the case where the three-dimensional object OB can be molded without using the support portion 904, the support portion 904 may not be provided.

The raised portion 905 is a portion that separates the cutting portion 903 and the table 300 to suppress interference between the cutting unit 200 and the table 300 when cutting work is performed on the three-dimensional shaped object OB. For example, the data generation unit 16 arranges the enhancement unit 905 at a position designated by the user. When the cutting portion 903 is removed from the shaping portion 901 shaped in accordance with the second shape SP2 by cutting, the data generating portion 16 determines whether or not the cutting unit 200 and the table 300 interfere with each other, and in the case where it is determined that the cutting unit 200 and the table 300 interfere with each other, the data generating portion 16 may be provided with the lifting portion 905. In the present embodiment, the elevation portion 905 is provided between the modeling portion 901 and the support portion 904 and the table 300. In addition, when the three-dimensional object OB can be cut without using the raised portion 905, the raised portion 905 may not be provided.

The data generation portion 16 determines in step S140 whether the length Ls of the cutting portion 903 in the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction. The cuttable length Le is a maximum length that can cut the object to be machined in a predetermined direction. For example, when the cutting tool 210 is inserted into the hollow portion from one end of a pipe arranged in the X direction with the central axis, and cuts the cutting margin provided on the inner wall surface of the pipe, the distance along the X direction from the one end of the pipe to the limit position where cutting is possible is the cutting length Le of the cutting tool 210 in the X direction. The data generation portion 16 determines whether the length Ls of the cutting portion 903 in the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction, using the second shape data and the information about the cutting tool 210. In addition, the X direction is also referred to as a first direction, and the cuttable length Le is also referred to as a cuttable depth or a first length.

Fig. 8 is a perspective view showing the third shape SP3 indicated by the third shape data in the present embodiment. Referring to fig. 5 and 8, when it is determined in step S140 that the length Ls of the cutting portion 903 in the X direction is longer than the cuttable length Le in the X direction of the cutting tool 210, the data generation portion 16 generates third shape data representing a third shape SP3 using the second shape data in step S150. The third shape SP3 is a shape of the three-dimensional shaped object OB divided into a plurality of parts. The data generation portion 16 divides the second shape SP2 so that the length of the cutting portion 903 in the X direction of each portion is shorter than the cuttable length Le of the cutting tool 210 in the X direction, setting a third shape SP 3.

In the present embodiment, the length Ls of the cutting portion 903 in the X direction in the linear portion 820 is longer than the cuttable length Le of the cutting tool 210 in the X direction. Accordingly, the data generation section 16 divides the second shape SP2 into the first part 910, the second part 920, and the third part 930, and generates the third shape SP 3. The first portion 910 is a portion including a curved portion 810 and a portion of a straight portion 820. The second portion 920 is a portion including a portion of the straight portion 820 adjacent to the first portion 910. The third portion 930 is a portion including a part of the straight portion 820 adjacent to the second portion 920. The length L1 of the cut portion 903 in the X direction in the first portion 910, the length L2 of the cut portion 903 in the X direction in the second portion 920, and the length L3 of the cut portion 903 in the X direction in the third portion 930 are respectively shorter than the cuttable length Le of the cutting tool 210 in the X direction.

In the present embodiment, the data generation section 16 divides the second shape SP2 by a plane inclined with respect to the table 300 so that interference between the nozzle 61 and the three-dimensional shaped object OB does not occur at the time of shaping. The second shape SP2 is divided such that the first end face 911 on the second portion 920 side in the first portion 910 is inclined at an acute angle with respect to the table 300, and the second end face 921 on the third portion 930 side in the second portion 920 is inclined at an acute angle with respect to the table 300. The data generation unit 16 divides the second shape SP2 such that the inclination angle θ 1 of the first end face 911 with respect to the stage 300 is smaller than the inclination angle θ n of the side face of the nozzle 61 with respect to the stage 300. The data generation unit 16 divides the second shape SP2 such that the inclination angle θ 2 of the second end face 921 with respect to the stage 300 is the same as the inclination angle θ 1 of the first end face 911 with respect to the stage 300.

In step S140, when it is not determined that the length Ls of the cutting portion 903 in the X direction is longer than the cuttable length Le of the cutting tool 210 in the X direction, the data generation portion 16 omits the processing in step S150 and proceeds to the next processing.

Referring to fig. 5, in step S160, the data generation unit 16 generates cross-sectional data using the third shape data. The cross-sectional data is data indicating the cross-sectional shape when the third shape SP3 is cut off in a plane parallel to the modeling surface 310 of the table 300. The data generating unit 16 cuts the third shape SP3 at intervals according to the thickness of one layer of the modeling material stacked on the table 300 by the three-dimensional modeling apparatus 10, and generates a plurality of pieces of cross-sectional data. For example, the thickness of a layer of modeling material that is laminated on the table 300 by the three-dimensional modeling apparatus 10 is set by the user. In addition, in the case where the third shape data is not generated because step S150 is omitted, the data generation portion 16 generates the cross-sectional data using the second shape data.

Fig. 9 is an explanatory diagram schematically showing the modeling path and the cutting path generated by the data generation unit 16. In fig. 9, the modeling path is indicated by a solid line and the cutting path is indicated by a broken line. Referring to fig. 5 and 9, in step S170, the data generation unit 16 generates a shaping path for creating the three-dimensional shaped object OB using the respective cross-sectional data, and generates a cutting path using the third shape data. The modeling path is a scanning path of the nozzle 61 moving while discharging the modeling material with respect to the table 300. The cutting path is a scanning path of the cutting tool 210 relative to the table 300 while cutting the laminated modeling material. In the present embodiment, the data generation section 16 generates a first modeling path Pm1 for modeling the first part 910, a second modeling path Pm2 for modeling the second part 920, a third modeling path Pm3 for modeling the third part 930, a first cutting path Pcl for cutting the first part 910, a second cutting path Pc2 for cutting the second part 920, and a third cutting path Pc3 for cutting the third part 930.

Referring to fig. 5, in step S180, the data generation unit 16 generates and outputs modeling data and cutting data. The modeling data indicates, in addition to the modeling path, information set by the user regarding, for example, the discharge amount, which is the flow rate of the modeling material discharged from the nozzle 61, the rotational speed of the drive motor 32 for rotating the grub screw 40, the temperature of the heater 58 of the barrel 50, the temperature of the reheating unit 70, and the like. The cutting data indicates, for example, information set by the user about the rotational speed of the cutting tool 210, the feed speed of the cutting tool 210, and the like, in addition to the cutting path. The data generating unit 16 generates and outputs modeling data and cutting data represented by, for example, G code or M code.

In the present embodiment, the modeling data and the cutting data are represented in one data. The data includes a first modeling data portion for modeling the first portion 910, a first cutting data portion for cutting the first portion 910, a second modeling data portion for modeling the second portion 920, a second cutting data portion for cutting the second portion 920, a third modeling data portion for modeling the third portion 930, and a third cutting data portion for cutting the third portion 930. The first shaping data portion, the first cutting data portion, the second shaping data portion, the second cutting data portion, the third shaping data portion, and the third cutting data portion are set in this order.

Fig. 10 is an explanatory view schematically showing modeling data and cutting data in the present embodiment. The modeling data is read and interpreted in the order from the top to the bottom in fig. 10. Fig. 10 shows the first modeling data portion Dm1 and the first cutting data portion Dc 1. A command COM1 for moving the nozzle 61 to the coordinates (X, Y, Z) ═ 110, 50, and 20 is set in the first modeling data portion Dm 1. The coordinates represent the relative position of the nozzle 61 with respect to the table 300. While the nozzle 61 is moved from the coordinate (X, Y, Z) (110, 50, 20) to the coordinate (X, Y, Z) (100, 50, 20), a command COM 2 for ejecting 10 units of the modeling material from the nozzle 61 is set. While the nozzle 61 is moved from the coordinate (X, Y, Z) (100, 50, 20) to the coordinate (X, Y, Z) (100, 45, 20), the command COM 3 for ejecting 5 units of the modeling material from the nozzle 61 is set. The command COM4 for ending the molding of the first part 910 is set after the drawing is omitted halfway. In the first data part for cutting Dc1, a command COM5 for moving the cutting tool 210 to the coordinate (X, Y, Z) ═ 200, 50, 20 is set. A command COM6 for moving the cutting tool 210 from the coordinate (X, Y, Z) (200, 50, 20) to the coordinate (X, Y, Z) (100, 50, 20) at a feed speed of 10 units is set. Thereafter, a command COM7 for ending the cutting of the first part 910 is set.

Fig. 11 is a flowchart showing the content of the shaping process for realizing the production of the three-dimensional shaped object OB in the present embodiment. When the user performs a predetermined start operation on an operation panel provided in the three-dimensional modeling apparatus 10 or the information processing apparatus 15 connected to the three-dimensional modeling apparatus 10, the control unit 500 of the three-dimensional modeling apparatus 10 executes the process.

First, in the data acquisition step of step S210, the control unit 500 acquires modeling data and cutting data from the information processing device 15. In the present embodiment, the control unit 500 acquires the modeling data and the cutting data from the information processing device 15 by wire communication. The control unit 500 may acquire the modeling data and the cutting data from the information processing device 15 by wireless communication, or may acquire the modeling data and the cutting data from the information processing device 15 via a recording medium such as a USB memory.

Next, in the material producing step of step S220, the control unit 500 melts the material by controlling the rotation of the grub screw 40 and the temperature of the heater 58 built in the cylinder 50, thereby producing the modeling material. This control is also referred to as material generation control. In the material producing step, the material contained in the material supply portion 20 is supplied from the side surface 43 of the rotating grub screw 40 to the material introduction portion 48 via the supply path 22. The rotation of the grub screw 40 causes the material supplied to the material introduction portion 48 to be carried into the volute portion 47. By the rotation of the grub screw 40 and the heating of the heater 58, at least a part of the material carried into the volute portion 47 is melted, and a paste-like molding material having fluidity is produced. The produced molding material is transported toward the central portion 46 in the volute portion 47, and is supplied to the nozzle 61 from the communication hole 56. In addition, during the molding process described later, the molding material will continue to be produced.

In the partial molding step of step S230, the control unit 500 controls the discharge unit 100 and the moving mechanism 400 based on the molding data to mold the laminate in which the molding material is laminated on the table 300. The length of the laminated body in the X direction is shorter than the cuttable length Le of the cutting tool 210 in the X direction. This control is called a partial build control. The control section 500 performs partial modeling control to eject the modeling material from the nozzle 61 toward the table 300 while changing the relative position between the nozzle 61 of the ejection unit 100 and the table 300, and to model the stacked body on the table 300. Laminating the molding material means that the molding material is further disposed on the previously disposed molding material. Further, laminating the molding materials also means arranging the molding materials continuously. For example, when the molding material is continuously discharged from the nozzle 61 and is continuously disposed on the table 300, the portion of the molding material disposed in contact with the table 300 is referred to as a first layer, and the portion of the molding material disposed on the first layer is referred to as a second layer.

In the partial cutting process of step S240, the control unit 500 controls the cutting unit 200 and the moving mechanism 400 based on the cutting data, and cuts the cutting allowance provided in the stacked body in the X direction using the cutting tool 210. This control is called partial cut control. The control part 500 brings the rotating cutting tool 210 into contact with the cutting allowance of the laminated body while changing the relative position between the cutting tool 210 and the table 300 by performing partial cutting control, thereby processing the laminated body to a desired size and surface roughness.

In step S250, the control unit 500 determines whether the creation of the three-dimensional object OB is completed. The three-dimensional object OB is formed after the three-dimensional object OB is formed according to the forming path indicated in the forming data and is cut according to the cutting path indicated in the cutting data. The control unit 500 can determine whether or not the creation of the three-dimensional object OB is completed using the data for modeling and the data for cutting.

When it is determined in step S250 that the creation of the three-dimensional object OB is completed, the control unit 500 ends the process. On the other hand, when it is determined in step S250 that the creation of the three-dimensional object OB is not completed, the control unit 500 controls the temperature of the reheating unit 70 in the heating step of step S260 to heat the end face of the laminated body. This control is called heating control. The control unit 500 performs heating control to heat the end surfaces of the stacked body for a predetermined time by using the reheating unit 70. The heating time is set according to the kind of material and the temperature of the reheating part 70. For example, the control section 500 sets the heating time using a map indicating the relationship between the temperature of the reheating section 70 and the heating time. The map can be set by examining, through a test performed in advance, the time until the temperature of the end face of the laminate reaches a predetermined temperature exceeding the glass transition point of the material. In addition, the control section 500 may set the heating time using a function representing the relationship between the temperature of the reheating section 70 and the heating time, instead of using a map.

After the heating step in step S260, control unit 500 returns the process to step S230, and repeats the processes from step S230 to step S250. The control unit 500 repeatedly executes the heating process of step S260, the partial shaping process of step S230, and the partial cutting process of step S240 until it is determined in step S250 that the formation of the three-dimensional shaped object OB has been completed, thereby connecting the stacked bodies along the X direction and shaping the three-dimensional shaped object OB having a length along the X direction longer than the cutting length Le of the cutting tool 210 in the X direction.

Fig. 12 is a process diagram showing a first partial molding step in the present embodiment. The first partial molding process means a first partial molding process. In fig. 12, the cutting portion 903 is indicated by a two-dot chain line. In the first partial modeling process, the control unit 500 performs the partial modeling control in step S230 based on the data for modeling, thereby laminating the modeling material on the table 300, and modeling is performed such that the length L1 of the cut portion 903 in the X direction is shorter than the cuttable length Le of the cutting tool 210 in the X direction. The laminated body molded in the first part molding process is a first part 910. The first portion 910 may be referred to as a first laminate. The first portion 910 has a first end face 911, and the first end face 911 is an end face connected to the second portion 920 in a second portion forming step described later. The inclination angle θ 1 of the first end face 911 with respect to the stage 300 is smaller than the inclination angle θ n of the side face of the nozzle 61 with respect to the stage 300. The first portion 910 molded on the work table 300 is solidified by the work table 300 and radiating heat in the atmosphere.

Fig. 13 is a cross-sectional view along line XIII-XIII of the first portion 910. The first portion 910 includes a molding portion 901, a support portion 904, and an elevated portion 905. In fig. 13, different kinds of hatching are applied to the modeling portion 901, the support portion 904, and the raised portion 905. The shaping portion 901 has a main body portion 902 and a cutting portion 903. After the molding process is completed, the support portion 904 is removed. In the present embodiment, the support portion 904 is provided so that the lower surface of the outer peripheral portion of the modeling portion 901 can be supported. After the molding process is completed, the raised portion 905 is removed. In the present embodiment, the elevation portion 905 is provided between the lower surfaces of the shaping portion 901 and the support portion 904 and the table 300.

Fig. 14 is a process diagram illustrating a first partial cutting step in the present embodiment. The first partial cutting process means a first partial cutting process. In the first partial cutting process, the control part 500 cuts the cutting part 903 of the first part 910 by performing the partial cutting control of step S240. In the present embodiment, the control part 500 inserts the cutting tool 210 into the hollow portion of the first part 910 having a pipe shape with the rotation axis of the cutting tool 210 directed in the X direction, and causes the rotating cutting tool 210 to contact the cutting part 903 of the first part 910, thereby cutting the cutting part 903 of the first part 910.

Fig. 15 is a process diagram illustrating the first heating step in the present embodiment. The first heating step means a first heating step. In the first heating step, the control unit 500 performs the heating control of step S260 to heat the first end face 911 of the first portion 910. The control unit 500 controls the temperature of the reheating unit 70 based on the modeling data to heat the first end surface 911.

Fig. 16 is a process diagram showing a second partial molding step in the present embodiment. The second partial molding process means a second partial molding process. In fig. 16, the cutting portion 903 is indicated by a two-dot chain line. In the second partial modeling process, the control unit 500 performs the partial modeling control of step S230 based on the data for modeling, thereby laminating the modeling material on the table 300 in such a manner that the length L2 of the cutting portion 903 in the X direction is shorter than the cuttable length Le of the cutting tool 210 in the X direction. The laminated body molded in the second part molding process is a second part 920. The second portion 920 may be referred to as a second stack. The second portion 920 has a second end surface 921, and the second end surface 921 is an end surface on a side connected to the third portion 930 in a third portion forming process described later. The inclination angle θ 2 of the second end surface 921 to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 to the stage 300. The second portion 920 formed on the work table 300 is solidified by the work table 300, the first portion 910 and heat emitted in the atmosphere.

Fig. 17 is a process diagram illustrating a second partial cutting step in the present embodiment. The second partial cutting process means a second partial cutting process. In the second partial cutting process, the control part 500 cuts the cut part 903 of the second part 920 by performing the partial cutting control of step S240. In the present embodiment, the control part 500 inserts the cutting tool 210 into the hollow portion having the second portion 920 having a pipe shape with the rotation axis of the cutting tool 210 directed in the X direction, and cuts the cutting portion 903 of the second portion 920 by bringing the rotating cutting tool 210 into contact with the cutting portion 903 of the second portion 910.

Fig. 18 is a process diagram illustrating a second heating step in the present embodiment. The second heating step means a second heating step. In the second heating process, the control part 500 heats the second end face 921 of the second part 920 by performing the heating control of step S260. The control section 500 heats the second end surface 921 by controlling the temperature of the reheating section 70 according to the modeling data.

Fig. 19 is a process diagram showing a third partial molding step in the present embodiment. The third partial molding process means a third partial molding process. In fig. 19, the cutting portion 903 is indicated by a two-dot chain line. In the third partial shaping process, the control part 500 performs the partial shaping control of step S230 so as to be connected to the second end face 921 of the second part 920 along the X direction, shaping a laminated body having a length L3 in the X direction shorter than the cuttable length Le of the cutting tool 210 in the X direction. The laminated body molded in the third part molding process is a third part 930. The third portion 930 may be referred to as a third laminate. The third portion 930 formed on the work table 300 is solidified by the work table 300, the second portion 920 and heat emitted in the atmosphere.

Fig. 20 is a process diagram showing a third partial cutting step in the present embodiment. The third partial cutting process means a third partial cutting process. In the third partial cutting process, the control part 500 cuts the cut part 903 of the third part 930 by performing the partial cutting control of step S240. In the present embodiment, the control unit 500 inserts the cutting tool 210 into the hollow portion of the third portion 930 having a tubular shape with the rotation axis of the cutting tool 210 oriented in the X direction, and cuts the cutting portion 903 of the third portion 930 by bringing the rotating cutting tool 210 into contact with the cutting portion 903 of the third portion 930.

In the present embodiment, the control unit 500 ends the forming step after the third partial cutting step. After completing the modeling process, the user separates the three-dimensional model OB from the table 300, removes the support 904 and the raised portion 905, or sinters the three-dimensional model OB in a furnace to complete the three-dimensional model OB according to the design shape.

According to the method of forming the three-dimensional shaped object OB of the present embodiment described above, when the control unit 500 performs the cutting process after the first lamination of the shaping materials, the three-dimensional shaped object OB in which the cutting tool 210 cannot reach and the shape of the remaining portion of the cutting unit 903 is generated is divided into the first portion 910, the second portion 920, and the third portion 930, and therefore, a three-dimensional shaped object OB in a desired shape without the remaining cutting unit 903 can be generated. Therefore, the degree of freedom of the shape of the three-dimensional shaped object OB that can be produced by laminating the shaping materials and cutting can be improved. In particular, in the present embodiment, the length Ls of the cutting portion 903 in the X direction provided on the inner wall surface 825 of the three-dimensional shaped object OB is longer than the cutting length Le of the cutting tool 210 in the X direction, and therefore, when cutting is performed after the first lamination of the shaped materials, the cutting tool 210 cannot reach and a portion where the cutting portion 903 remains is generated on the inner wall surface 825. Therefore, the controller 500 divides the three-dimensional object OB into the first portion 910, the second portion 920, and the third portion 930 such that the length L1 of the cutting portion 903 in the X direction in the first portion 910, the length L2 of the cutting portion 903 in the X direction in the second portion 920, and the length L3 of the cutting portion 903 in the X direction in the third portion 930 are shorter than the cutting length Le of the cutting tool 210 in the X direction. Therefore, a three-dimensional shaped object OB having a desired shape without the surplus cut portion 903 on the inner wall surface 825 can be formed.

In the present embodiment, the control unit 500 molds the first portion 910 so that the inclination angle θ 1 of the first end surface 911 with respect to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 with respect to the stage 300 in the first portion molding step, and molds the second portion 920 so that the inclination angle θ 2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 with respect to the stage 300 in the second portion molding step. Therefore, interference between the first part 910 and the nozzle 61 in the second part molding process and interference between the second part 920 and the nozzle 61 in the third part molding process can be suppressed.

In the present embodiment, the control unit 500 performs a first heating step of heating the first end face 911 of the first portion 910 between the first partial cutting step and the second partial shaping step, and performs a second heating step of heating the second end face 921 of the second portion 920 between the second partial cutting step and the third partial shaping step. Accordingly, the adhesion between the first portion 910 and the second portion 920 and the adhesion between the second portion 920 and the third portion 930 may be improved. Therefore, the mechanical strength of the three-dimensional shaped object OB shaped by dividing into the first part 910 to the third part 930 can be improved.

In the present embodiment, the control unit 500 molds the raised portion 905 between the molding portion 901 and the table 300 in each portion molding step. Therefore, interference between the cutting unit 200 and the table 300 in each portion cutting process can be suppressed.

In the present embodiment, a granular ABS resin material is used, but various materials such as a material having a thermoplastic property, a metal material, and a ceramic material can be used as a main material for molding the three-dimensional shaped object as a material used for the ejection unit 100. Here, "main material" means a material forming the center of the shape of the three-dimensional shaped object, and means a material having a content of 50% by weight or more in the three-dimensional shaped object. The molding material includes a material obtained by melting these main materials as a single body and a material obtained by melting a part of components contained in the main materials to form a paste.

In the case of using a material having thermoplasticity as the main material, the modeling material is generated by plasticizing the material in the melting section 30. "plasticizing" means heating and melting a material having thermoplastic properties.

As the material having thermoplasticity, for example, any one of the following or a combination of two or more of the thermoplastic resin materials can be used.

Examples of thermoplastic resin materials

General-purpose engineering plastics such as polypropylene resin (PP), polyethylene resin (PE), polyacetal resin (POM), polyvinyl chloride resin (PVC), polyamide resin (PA), acrylonitrile butadiene styrene resin (ABS), polylactic acid resin (PLA), polyphenylene sulfide resin (PPs), Polycarbonate (PC), modified polyphenylene ether, polybutylene terephthalate, polyethylene terephthalate, and engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide, and Polyetheretherketone (PEEK).

The thermoplastic material may contain additives such as wax, flame retardant, antioxidant, and heat stabilizer in addition to pigments, metals, and ceramics. The material having thermoplasticity is plasticized and changed into a molten state in the melting section 30 by the rotation of the grub screw 40 and the heating of the heater 58. The molding material thus produced is discharged from the nozzle hole 62 and then solidified by a decrease in temperature.

It is desirable that the material having the thermoplastic is ejected from the nozzle hole 62 in a state of being heated above its glass transition point and completely melted. For example, it is desirable that the glass transition point of the ABS resin be about 120 ℃ and about 200 ℃ when ejected from the nozzle hole 62. In order to eject the molding material in such a high temperature state, a heater may be provided around the nozzle hole 62.

In the ejection unit 100, instead of the material having the thermoplastic property described above, for example, the following metal material may be used as a main material. In this case, it is desirable that a component melted at the time of producing the modeling material is mixed with a powder material obtained by powdering the following metal material and is charged into the melting section 30.

Examples of the metallic materials

Magnesium (Mg), iron (Fe), cobalt (Co), chromium (Cr), aluminum (Al), titanium (Ti), copper (Cu), nickel (Ni) or an alloy containing one or more of these metals.

Examples of alloys

Maraging steel, stainless steel, cobalt chromium molybdenum, titanium alloy, nickel alloy, aluminum alloy, cobalt chromium alloy.

In the ejection unit 100, instead of the metal material, a ceramic material may be used as a main material. As the ceramic material, for example, oxide ceramics such as silica, titania, alumina, and zirconia, non-oxide ceramics such as aluminum nitride, and the like can be used. When the metal material or the ceramic material as described above is used as the main material, the modeling material disposed on the table 300 may be solidified by, for example, laser irradiation or sintering with hot air.

The powder material of the metal material or the ceramic material charged into the material supply unit 20 may be a mixed material obtained by mixing a plurality of kinds of single metal powder, alloy powder, and ceramic material powder. In addition, the powder material of the metal material or the ceramic material may be coated by, for example, the thermoplastic resin or other thermoplastic resin exemplified above. In this case, the thermoplastic resin may be melted in the melting portion 30 to exhibit fluidity.

For example, the following solvent may be added to the powder material of the metal material or the ceramic material charged into the material supply unit 20. The solvent may be used in combination of one or more selected from the following.

Examples of the solvent

Water; (poly) alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetates such as ethyl acetate, n-propyl acetate, isopropyl acetate, n-butyl acetate, isobutyl acetate, etc.; 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 acetylacetone; alcohols such as ethanol, propanol, and butanol; tetraalkylammonium acetates; sulfoxide solvents such as dimethyl sulfoxide and diethyl sulfoxide; pyridine solvents such as pyridine, gamma-picoline and 2, 6-lutidine; tetraalkylammonium acetates (e.g., tetrabutylammonium acetate, etc.); butyl carbitol acetate plasma liquid.

For example, the following binder may be added to the powder material of the metal material or the ceramic material to be charged into the material supply unit 20.

Examples of Adhesives

Acrylic, epoxy, silicone, cellulose or other synthetic resins, PLA (polylactic acid), PA (polyamide), PPS (polyphenylene sulfide), PEEK (polyether ether ketone), or other thermoplastic resins.

B. Other embodiments are as follows:

(B1) in each of the above embodiments, in the first heating step, the control unit 500 heats the first end surface 911 of the first part 910 using the reheating unit 70, and in the second heating step, the control unit 500 heats the second end surface 921 of the second part 920 using the reheating unit 70. On the other hand, the first heating step and the second heating step may not be performed.

(B2) In the above embodiment, in the first heating step, the control unit 500 heats the first end face 911 of the first part 910 for a predetermined time by using the reheating unit 70, and in the second heating step, the control unit 500 heats the second end face 921 of the second part 920 for a predetermined time by using the reheating unit 70. On the other hand, in each heating step, the control unit 500 may heat the end surfaces 911 and 921 using the reheating unit 70 until the end surfaces 911 and 921 reach a predetermined temperature. For example, the control unit 500 may acquire the temperature of each of the end surfaces 911 and 921 using a temperature sensor, and stop heating by the reheating unit 70 when the acquired temperature reaches a predetermined temperature equal to or higher than the glass transition point of the material. In this case, the adhesiveness between the respective portions 910 to 930 can be more reliably improved. As the temperature sensor, for example, a contact thermometer such as a thermocouple or a noncontact thermometer such as an infrared thermometer can be used. The predetermined temperature is set in advance according to the kind of the material.

(B3) In the above embodiment, the control unit 500 molds the first portion 910 so that the inclination angle θ 1 of the first end surface 911 with respect to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 with respect to the stage 300 in the first portion molding step, and molds the second portion 920 so that the inclination angle θ 2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 with respect to the stage 300 in the second portion molding step. On the other hand, in the respective-portion forming step, the control unit 500 may form the respective end surfaces 911 and 921 such that the inclination angle θ n of the side surfaces of the nozzle 61 with respect to the table 300 is equal to or greater than the respective end surfaces 910 and 920. In this case, for example, in the first cutting step, by performing cutting so that the inclination angle θ 1 of the first end face 911 with respect to the table 300 is smaller than the inclination angle θ n of the side face of the nozzle 61 with respect to the table 300, the interference between the first portion 910 and the nozzle 61 in the second portion forming step can be suppressed. In the second cutting step, the cutting process is performed so that the inclination angle θ 2 of the second end surface 921 with respect to the stage 300 is smaller than the inclination angle θ n of the side surface of the nozzle 61 with respect to the stage 300, whereby interference between the second portion 920 and the nozzle 61 in the third portion forming step can be suppressed.

(B4) In the above embodiment, the length Ls of the cutting portion 903 in the X direction provided on the inner wall surface 825 of the three-dimensional shaped object OB is larger than the cutting length Le of the cutting tool 210 in the X direction. On the other hand, the length Ls of the cutting portion 903 in the X direction may be shorter than the cuttable length Le of the cutting tool 210 in the X direction.

(B5) In the above embodiment, in the data generation process, the data generation portion 16 divides the second shape SP2 in such a manner that the lengths L1 to L3 of the cutting portion 903 of the respective portions 910 to 930 in the X direction are shorter than the cuttable length Le of the cutting tool 210 in the X direction. On the other hand, the data generation section 16 divides the modeling path in such a manner that the lengths L1 to L3 of the cutting portion 903 of the respective portions 910 to 930 in the X direction are shorter than the cuttable length Le of the cutting tool 210 in the X direction. Even in this case, when the cutting process is performed after the molding materials are laminated once, the three-dimensional object OB in which the cutting portion 903 is left without being reached by the cutting tool 210 can be divided into the first portion 910, the second portion 920, and the third portion 930.

(B6) Fig. 21 is an explanatory view showing another embodiment of three-dimensional shaped object OB 2. Fig. 21 shows a three-dimensional shaped object OB2 after the third partial shaping step and before the third partial cutting step. The three-dimensional shaped object OB2 has a linear tubular shape. The three-dimensional shaped object OB2 is arranged on the table 300 such that the center axis CL of the tube is parallel to the Z direction. In the three-dimensional shaped object OB2, the cut portion 903 is provided on the inner wall surface 825 of the tube. Since the length Ls of the cutting portion 903 in the Z direction provided in the three-dimensional shaped object OB2 is longer than the cutting length Le of the cutting tool 210 in the Z direction, when the cutting process is performed after the first lamination of the shaped materials to form the three-dimensional shaped object OB2, the cutting tool 210 cannot reach and a surplus portion of the cutting portion 903 is generated. Therefore, the controller 500 divides the three-dimensional shaped object OB2 into the first portion 910b, the second portion 920b, and the third portion 930b so that the length L1 of the cut portion 903 in the Z direction in the first portion 910b, the length L2 of the cut portion 903 in the Z direction in the second portion 920b, and the length L3 of the cut portion 903 in the Z direction in the third portion 930b are shorter than the cuttable length Le of the cutting tool 210 in the Z direction. Therefore, a three-dimensional shaped object OB2 having a desired shape can be formed without leaving the cut portion 903.

(B7) Fig. 22 is an explanatory view showing another embodiment of three-dimensional shaped object OB 3. Fig. 22 shows a three-dimensional shaped object OB3 after the third partial shaping step and before the third partial cutting step. Three-dimensional shaped object OB3 has a curved tubular shape. The three-dimensional shaped object OB3 is arranged on the table 300 such that the center axis CL of the tube is parallel to the table 300. The three-dimensional shaped object OB3 has, in order from one end, a portion extending in a first direction parallel to the X direction, a portion intersecting the X direction and extending in a second direction parallel to the table 300, and a portion extending in the first direction. In the three-dimensional shaped object OB3, the cut portion 903 is provided on the inner wall surface 825 of the tube. A length Ls of the cutting portion 903 provided in the three-dimensional shaped object OB3 in the first direction is longer than a cuttable length Le of the cutting tool 210 in the first direction. Since the three-dimensional shaped object OB3 has a curved tube shape, when the three-dimensional shaped object OB3 is formed by performing cutting after the first lamination of the shaped materials, the cutting tool 210 cannot reach and a portion of the cutting portion 903 remains. Therefore, the controller 500 divides the three-dimensional object OB3 into a first portion 910c, a second portion 920c, and a third portion 930c so that the first portion 910b, the second portion 920b, and the third portion 930b form linear tube shapes, respectively. At this time, the controller 500 divides the three-dimensional shaped object OB2 into a first portion 910c, a second portion 920c, and a third portion 930c so that the length L1 of the cutting portion 903 in the first direction in the first portion 910c is shorter than the cutting length Le of the cutting tool 210 in the first direction, the length L2 of the cutting portion 903 in the second direction in the second portion 920c is shorter than the cutting length Le of the cutting tool 210 in the second direction, and the length L3 of the cutting portion 903 in the first direction in the third portion 930c is shorter than the cutting length Le of the cutting tool 210 in the first direction. Therefore, a three-dimensional shaped object OB3 having a desired shape can be formed without leaving the cut portion 903.

(B8) Fig. 23 is an explanatory diagram showing a schematic configuration of the ejection unit 100b as another embodiment. The ejection unit 100b may include a melting section 30b having an in-line screw 140 and a cylinder 50 b. The inline screws 140 have a substantially cylindrical shape having a length in the direction of the central axis RX greater than a diameter. The inline screws 140 are arranged such that the central axis RX is parallel to the Z direction. A spiral groove portion 145 is provided on a side surface of the column of the inline screw 140. The inline screws 140 are rotated by a drive motor 32 connected to the upper end. The cylinder 50b has a cylindrical shape covering the outer periphery of the inline screw 140. In the cylinder 50b, a screw facing surface 52b facing the inline screws 140 is provided on an inner wall surface of the cylinder. The cylinder 50b incorporates a heater 58b at a position facing the groove portion 145 of the inline screw 140. On the bottom surface of the cylinder barrel 50b, a communication hole 56 is provided on the center axis RX of the inline screw 140. Even in this manner, the melting portion 30b can melt the material supplied from the material supply portion 20 to the groove portion 145 by the rotation of the inline screw 140 and the heating of the heater 58b to produce the molding material, and can feed the molding material from the communication hole 56. Additionally, the inline screws 140 may be simply referred to as screws. The heater 58b may be referred to as a heating unit.

C. Other forms:

the present disclosure is not limited to the above-described embodiments, and may be implemented in various ways within a scope not departing from the spirit thereof. For example, the present disclosure can also be achieved in the following manner. In order to solve part or all of the problems of the present disclosure or achieve part or all of the effects of the present disclosure, the technical features in the above-described embodiments corresponding to the technical features in the respective embodiments described below may be appropriately replaced or combined. In addition, if technical features thereof are not described as indispensable in the present specification, they may be deleted as appropriate.

(1) According to a first aspect of the present invention, there is provided a method of forming a three-dimensional shaped object using a cutting tool capable of cutting a maximum first length in a predetermined cutting direction. The method for molding the three-dimensional molded object comprises the following steps: a first part molding step of molding a first part having a length in a first direction shorter than the first length by laminating molding materials; a first partial cutting step of cutting the first part with the cutting tool having the cutting direction along the first direction; a second part molding step of molding a second part by laminating the molding material, the second part being connected to a first end surface of the first part in the first direction, a length of the second part in the second direction being shorter than the first length; and a second partial cutting step of cutting the second portion in the second direction by the cutting tool having the cutting direction in the second direction.

According to the method of forming a three-dimensional shaped object of this aspect, when the cutting process is performed after the first lamination of the forming materials, the three-dimensional shaped object in which the cutting tool does not reach and the portion where the cutting margin is left can be formed in a desired shape without leaving the cutting margin. Therefore, the degree of freedom of the shape of the three-dimensional shaped object that can be produced by laminating the shaping materials and cutting can be improved.

(2) In the method of forming a three-dimensional shaped object according to the above aspect, the first direction and the second direction may be the same direction.

According to the method of forming a three-dimensional shaped object of this aspect, a three-dimensional shaped object in which the cutting margin is provided along the first direction can be formed in a desired shape.

(3) In the method of forming a three-dimensional shaped object according to the above aspect, the first direction and the second direction may be different directions.

According to the method of forming a three-dimensional shaped object of this aspect, a three-dimensional shaped object in which a portion that cannot be reached by the cutting tool and has a surplus cutting margin can be formed in a desired shape by performing cutting work only from one direction.

(4) In the three-dimensional shaped object molding method according to the above aspect, at least either one of a length of the first portion and the second portion added together in the first direction and a length of the first portion and the second portion added together in the second direction is longer than the first length.

According to the method of forming a three-dimensional shaped object of this aspect, since the three-dimensional shaped object has a long shape, a portion where the cutting tool cannot reach and the cutting margin is left can be formed in a desired shape.

(5) In the method of forming a three-dimensional shaped object according to the above aspect, an inclination angle of the first end surface in the first portion with respect to a table on which the shaping material is stacked is smaller than an inclination angle of a side surface in a nozzle that ejects the shaping material with respect to the table.

According to the method of forming a three-dimensional formed object of this aspect, interference between the nozzle and the first portion can be suppressed when forming the second portion connected to the first portion.

(6) The method of forming a three-dimensional shaped object according to the above aspect may include a heating step of heating the first end surface of the first portion before the second portion forming step.

According to the method of forming a three-dimensional shaped object of this aspect, the adhesiveness between the first portion and the second portion can be improved, and thus the mechanical strength of the three-dimensional shaped object can be improved.

(7) In the method of forming a three-dimensional shaped object according to the above aspect, the first portion may have a raised portion that is formed in contact with a table and that ensures a distance between a cutting margin of the first portion cut in the first portion cutting step and the table.

According to the method of forming a three-dimensional shaped object of this aspect, when the cutting process is performed on the first portion, interference between the device for cutting and the table can be suppressed.

The present disclosure can be implemented in various ways other than the method of molding a three-dimensional shaped object. For example, the present invention can be realized as a three-dimensional modeling apparatus, a method for controlling a three-dimensional modeling apparatus, a data generation method, and the like.