阅读说明：本技术 三维造型物的制造方法及三维造型装置 (Method for manufacturing three-dimensional object and three-dimensional molding device ) 是由 姊川贤太 青柳大藏 渡边裕辅 于 2019-06-25 设计创作，主要内容包括：本申请涉及三维造型物的制造方法及三维造型装置,其抑制了伴随着造型材料固化时的收缩的翘曲。三维造型物的制造方法具备：第一造型工序,从喷嘴向造型台的造型面喷吐造型材料,使第一部分和第二部分在平行于造型面的第一方向上彼此分开地进行造型；固化工序,使第一部分和第二部分固化；以及第二造型工序,在所述固化工序之后,从喷嘴向第一部分与第二部分之间喷吐造型材料,对第三部分进行造型,该第三部分包括将第一部分的在第一方向上的端面与第二部分的在第一方向上的端面连续地接在一起的形状。(The present application relates to a method for manufacturing a three-dimensional shaped object and a three-dimensional shaping apparatus, which suppress warpage accompanying shrinkage when a shaping material is solidified. A method for producing a three-dimensional shaped object, comprising: a first molding step of ejecting a molding material from a nozzle to a molding surface of a molding table to mold the first portion and the second portion separately from each other in a first direction parallel to the molding surface; a curing step of curing the first part and the second part; and a second molding step of, after the curing step, discharging a molding material from the nozzle between the first portion and the second portion to mold a third portion having a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together.)

1. A method for manufacturing a three-dimensional shaped object, comprising:

a first molding step of ejecting a molding material from a nozzle onto a molding surface of a molding table to mold a first portion and a second portion separately from each other in a first direction parallel to the molding surface;

a curing step of curing the first part and the second part; and

and a second molding step of, after the solidifying step, discharging a molding material from the nozzle to a space between the first portion and the second portion to mold a third portion having a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together.

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

the end surface of the first portion and the end surface of the second portion bordering the third portion are inclined away from each other in a second direction perpendicular to the moulding surface away from the moulding surface.

3. The method of manufacturing a three-dimensional shaped object according to claim 2,

the first and second portions are each formed in a trapezoidal shape having a longer bottom side than an upper side, and each of the first and second portions is formed by cutting a plane parallel to the first direction and the second direction.

4. The method of manufacturing a three-dimensional shaped object according to claim 2 or 3,

a cross-sectional surface of the third portion, which is cut along a plane parallel to the first direction and parallel to the second direction, is a polygon having four or more sides including a first side contacting an end surface of the first portion and a second side contacting an end surface of the second portion,

at least one vertex of the polygon is located at a position farther from the modeling surface than a surface of the first portion and the second portion that is separated from the surface on the modeling surface side in the second direction.

5. The method of manufacturing a three-dimensional shaped object according to claim 4,

the polygon is a hexagon.

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

the method for producing a three-dimensional shaped object includes a first reheating step in which at least one of an end surface of the first portion and an end surface of the second portion that is in contact with the third portion is heated, between the curing step and the second shaping step.

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

the method for manufacturing a three-dimensional shaped object includes a second reheating step of heating a surface on a side separated from a surface on the shaping surface side in a direction perpendicular to a second direction of the shaping surface in at least one of the first portion, the second portion, and the third portion after the third portion is solidified,

after the second reheating step, the remaining portions of the three-dimensional object other than the first portion, the second portion, and the third portion are formed on the surface of the first portion, the second portion, and the third portion on the side separated from the surface on the forming surface side in the second direction.

8. The method of manufacturing a three-dimensional shaped object according to claim 4,

the method of manufacturing a three-dimensional shaped object includes a third shaping step of shaping a portion of the first portion that is in contact with the third portion so as to be separated from each other on a surface of the first portion that is separated from the shaping surface in the second direction and on a surface of the second portion that is separated from the shaping surface in the second direction, after the third portion is solidified.

9. The method of manufacturing a three-dimensional shaped object according to claim 1,

the method for manufacturing a three-dimensional shaped object includes a step of cutting at least a part of the solidified first portion, second portion, and third portion after solidifying the third portion.

10. The method of manufacturing a three-dimensional shaped object according to claim 1,

the method for producing a three-dimensional shaped object includes a material melting step of melting a material into the shaped material by a rotating planar screw.

11. A three-dimensional modeling apparatus is characterized by comprising:

a molding unit having a nozzle for ejecting a molding material;

a modeling table having a modeling surface for supporting a three-dimensional modeling object modeled by the modeling unit; and

a control section for controlling the molding unit,

the control section executes:

a first molding control for ejecting a molding material from the nozzle to the molding surface so that the first portion and the second portion are molded separately from each other in a first direction parallel to the molding surface;

a cure control to cure the first and second portions; and

and a second molding control for molding a third portion including a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together by discharging a molding material from the nozzle to between the first portion and the second portion after the solidification control.

Technical Field

The present invention relates to a method for manufacturing a three-dimensional shaped object and a three-dimensional shaping apparatus.

Background

For example, patent document 1 discloses a method for producing a three-dimensional shaped object, which comprises: the molten thermoplastic material is extruded from an extrusion nozzle that scans according to preset shape data onto a base, and the molten material is further laminated on the solidified material on the base.

Patent document 1: japanese patent application laid-open No. 2006-192710

In the method of manufacturing a three-dimensional shaped object of patent document 1, warping occurs due to shrinkage of the molten material during solidification, and there is a possibility that a three-dimensional shaped object of a desired shape cannot be manufactured.

Disclosure of Invention

According to one aspect of the present invention, a method of manufacturing a three-dimensional shaped object is provided. The method for producing a three-dimensional shaped object comprises: a first molding step of ejecting a molding material from a nozzle onto a molding surface of a molding table to mold a first portion and a second portion separately from each other in a first direction parallel to the molding surface; a curing step of curing the first part and the second part; and a second molding step of, after the curing step, discharging a molding material from the nozzle between the first portion and the second portion to mold a third portion having a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together.

According to an aspect of the present invention, there is provided a three-dimensional modeling apparatus. The three-dimensional modeling apparatus includes: a molding unit having a nozzle for ejecting a molding material; a modeling table having a modeling surface for supporting a three-dimensional modeling object modeled by the modeling unit; and a control section that controls the molding unit, the control section executing: a first molding control for ejecting a molding material from the nozzle to the molding surface so that the first portion and the second portion are molded separately from each other in a first direction parallel to the molding surface; a cure control to cure the first and second portions; and a second molding control for molding a third portion including a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together by discharging a molding material from the nozzle to between the first portion and the second portion after the curing control.

Drawings

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

Fig. 2 is an explanatory diagram showing a schematic configuration of the three-dimensional modeling unit.

Fig. 3 is a schematic perspective view showing a configuration of a lower surface side of the planar spiral.

Fig. 4 is a schematic plan view showing the upper surface side of the screw opposite portion.

Fig. 5 is a flowchart showing the contents of the three-dimensional modeling process in the first embodiment.

Fig. 6 is a process diagram illustrating a first molding step in the first embodiment.

Fig. 7 is a process diagram illustrating a first curing step in the first embodiment.

Fig. 8 is a process diagram illustrating a second molding step in the first embodiment.

Fig. 9 is a process diagram illustrating a second curing step in the first embodiment.

Fig. 10 is an explanatory diagram illustrating a situation of warpage of the three-dimensional shaped object in the comparative example.

Fig. 11 is a flowchart showing the contents of the three-dimensional modeling process in the second embodiment.

Fig. 12 is a process diagram showing a first reheating step in the second embodiment.

Fig. 13 is a flowchart showing the contents of the three-dimensional modeling process in the third embodiment.

Fig. 14 is a process diagram illustrating a second molding step in the third embodiment.

Fig. 15 is a process diagram illustrating a third molding step in the third embodiment.

Fig. 16 is a flowchart showing the contents of the three-dimensional modeling process in the fourth embodiment.

Fig. 17 is a process diagram illustrating a second reheating step in the fourth embodiment.

Fig. 18 is a process diagram illustrating a first upper layer molding step in the fourth embodiment.

Fig. 19 is a process diagram showing a second molding step in another embodiment.

Description of the reference numerals

10 a three-dimensional modeling apparatus; 20 a material supply unit; 22 a communication path; 30 a molding material generating section; 31 a screw shell; 32 a drive motor; 40 planar spiral pieces; 42 a groove part; 43 mountain parts; 44 a material flow inlet; 46 a central portion; 50 opposite portions of the spiral element; 54 a guide groove; 56 a communication hole; 58 a heater; 60 a discharge part; a nozzle 61; 62 an opening part; 65 flow path; 80 a moving mechanism; 81, a modeling table; 82 a temperature regulating heater; 90 a control unit; 96 a cutting tool; 99 a cutting unit; 100 molding units; 110. 110B a first section; 111 a first left side; 112 a first right side; 113 a first upper surface; 120. a second segment 120B; 121 a second left side; 122 a second right side; 123 a second upper surface; 130. 130B a third section; 131 a third left side; 132 a third right side; 133 a third upper surface; 140. 140B a fourth section; 141 a fourth left side; 142 a fourth right side; 143 a fourth upper surface; 150. 150B fifth section; 151 fifth left side; 152 a fifth right side; 153 fifth upper surface; 160 a sixth section; 170 a seventh stage; 180 eighth section; 210 a lower layer; 220, and (5) an upper layer.

Detailed Description

A. First embodiment

Fig. 1 is an explanatory diagram showing a schematic configuration of a three-dimensional modeling apparatus 10 according to a first embodiment. The three-dimensional modeling apparatus 10 in the present embodiment includes a control unit 90, a modeling table 81, a moving mechanism 80, a modeling unit 100, and a cutting unit 99. Hereinafter, the three-dimensional shaped object may be simply referred to as "shaped object". Arrows indicating X, Y, Z directions that are orthogonal to each other are shown in fig. 1. The X direction and the Y direction are directions parallel to a horizontal plane, and the Z direction is a direction opposite to a vertical direction. Arrows indicating the direction X, Y, Z are also shown in other figures as appropriate so that the directions shown correspond to those of fig. 1.

The three-dimensional modeling apparatus 10 models a modeled object by laminating a modeling material on a modeling table 81 moved by a moving mechanism 80 by a modeling unit 100. Fig. 1 schematically shows a state in which a shaped object OB is formed on the shaping table 81.

The control unit 90 is a control device that controls the operations of the molding unit 100, the cutting unit 99, and the moving mechanism 80 to execute a molding process for molding a molded object. The operation includes movement of the three-dimensional relative positions of the modeling unit 100 and the cutting unit 99 with respect to the modeling table 81.

In the present embodiment, the control unit 90 is configured 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. The control unit 90 performs various functions by the processor executing programs and commands read in the main storage device. Note that the control unit 90 may be realized by a configuration in which a plurality of circuits for realizing at least a part of each function are combined, instead of being configured by such a computer.

The molding table 81 is a flat plate-like member for accumulating a molding material. The modeling table 81 is disposed at a position facing the ejection section 60 of the modeling unit 100. The moving mechanism 80 is a moving unit that changes the relative positional relationship between the ejection unit 60 and the modeling table 81 under the control of the control unit 90. The moving mechanism 80 is constituted by a three-axis positioner that moves the modeling table 81 in three-axis directions of the direction X, Y, Z by the driving forces of three motors.

The cutting unit 99 is a cutting device that cuts the shaped object OB by rotating the cutting tool 96 attached to the shaft at the head tip. The cutting tool 96 may be, for example, a flat end mill, a ball end mill, or the like. The cutting unit 99 detects the position of the tip of the cutting tool 96 by a general position detection sensor and transmits the detection result to the control unit 90. The control unit 90 uses the detection result to control the relative positional relationship between the cutting tool 96 and the shaped object OB by the movement mechanism 80 described later, thereby performing cutting. The cutting unit 99 may be provided with a static eliminator such as an anion generator.

Fig. 2 is a schematic diagram showing a part of the components of the molding unit 100 for molding a three-dimensional molded object according to the first embodiment in a cross-sectional view. The molding unit 100 melts at least a part of the material in a solid state, and disposes the molding material in a paste state on the molding table 81. The molding unit 100 includes an ejection unit 60, a material supply unit 20, and a molding material generation unit 30.

The material supply unit 20 supplies the molding material generation unit 30 with the material. The material supply unit 20 is constituted by, for example, a hopper for containing a material. The material supply portion 20 has a discharge port at the lower side. The discharge port is connected to the molding material producing unit 30 via a communication path 22. The material is supplied to the material supply unit 20 in the form of particles, powder, or the like. In the present embodiment, a material of a granular ABS resin is used.

The molding material generating unit 30 generates a pasty molding material that has fluidity by melting at least a part of the material supplied from the material supply unit 20, and guides the molding material to the ejection unit 60. The modeling material producing unit 30 includes a screw housing 31, a drive motor 32, a planar screw 40, and a screw opposing unit 50. Fig. 3 and 4 described later show specific configurations of the planar spiral 40 and the spiral opposite portion 50, respectively.

The planar spiral 40 has a generally cylindrical shape with a height along its central axis that is less than the diameter. The planar spiral 40 is disposed such that its central axis is parallel to the Z direction and rotates about the central axis. The central axis of the planar spiral 40 coincides with its axis of rotation RX. The axis of rotation RX of the planar spiral 40 is shown in fig. 2 by a single-dot dashed line.

The planar screw 40 is housed within the screw housing 31. The driving motor 32 is connected to the upper surface Fa side of the planar screw 40, and the planar screw 40 rotates in the screw housing 31 by the rotational driving force generated by the driving motor 32. The drive motor 32 is driven under the control of the control section 90.

The planar spiral 40 has a groove 42 formed in a lower surface Fb which is a surface intersecting the rotation axis RX. The lower surface Fb of the planar spiral 40 faces the upper surface Ga of the spiral opposite portion 50, and the material is supplied from the material supply portion 20 into the groove portion 42 provided in the lower surface Fb of the planar spiral 40. The specific structure of the planar spiral 40 and the groove 42 thereof will be described later with reference to fig. 3.

A heater 58 for heating the material is embedded in the screw opposite portion 50. The material supplied into the groove portion 42 of the rotating planar screw 40 is at least partially melted by the rotation of the planar screw 40, flows along the groove portion 42, and is guided to the central portion 46 of the planar screw 40. The pasty material that has flowed into the central portion 46 is supplied as a molding material to the discharge portion 60 through the communication hole 56 provided in the center of the screw opposite portion 50.

The ejection section 60 includes a nozzle 61 and a flow path 65. The nozzle 61 is connected to the communication hole 56 of the screw opposite portion 50 through the flow path 65. The flow path 65 is a flow path of the molding material between the planar screw 40 and the nozzle 61. The nozzle 61 discharges the molding material produced in the molding material producing unit 30 from the opening 62 at the front end toward the molding table 81. Details of the nozzle 61 of the present embodiment will be described later.

As described above, the moving mechanism 80 changes the relative position of the modeling table 81 and the nozzle 61. The modeling table 81 is disposed at a position facing the opening 62 of the nozzle 61. The modeling table 81 has a modeling surface Ts which is a vertically upper surface when the modeling table 81 is disposed along the horizontal direction. In the present embodiment, the moving mechanism 80 moves the modeling table 81 relative to the nozzle 61 by the driving force of the three motors M. The modeling table 81 of the present embodiment incorporates a temperature control heater 82 for controlling the temperature of the modeling surface Ts under the control of the control unit 90.

In the modeling unit 100, instead of the configuration in which the modeling table 81 is moved by the moving mechanism 80, the moving mechanism 80 may be configured to move the nozzle relative to the modeling table 81 in a state in which the position of the modeling table 81 is fixed. Even in such a configuration, the relative positional relationship between the nozzle 61 and the modeling table 81 can be changed. In the following description, the term "moving distance of the nozzle 61" refers to a distance by which the nozzle 61 moves relative to the modeling table 81.

Fig. 3 is a schematic perspective view showing the structure of the planar spiral 40 on the lower surface Fb side. For easy understanding of the technique, the planar spiral 40 shown in fig. 3 shows the positional relationship between the upper surface Fa and the lower surface Fb shown in fig. 2 in a state of being oppositely oriented in the vertical direction. Fig. 3 shows the position of the rotation axis RX of the planar screw 40 when the modeling material generation unit 30 rotates, by a single-dot chain line diagram. As described with reference to fig. 2, the groove portion 42 is provided on the lower surface Fb of the planar spiral 40 facing the spiral facing portion 50. Hereinafter, the lower surface Fb is also referred to as a "groove forming surface Fb".

The central portion 46 of the groove forming surface Fb of the planar spiral 40 is configured as a recess connected to one end of the groove portion 42. The central portion 46 is opposed to the communication hole 56 of the screw opposed portion 50 shown in fig. 2. In the present embodiment, the center portion 46 intersects the rotation axis RX.

The groove portion 42 of the planar spiral 40 constitutes a so-called spiral groove. The groove 42 extends spirally from the central portion 46 to the outer periphery of the planar spiral 40. The groove portion 42 may be formed to extend in an involute curve or in a spiral. The groove forming surface Fb is provided with a ridge portion 43 which constitutes a side wall portion of the groove portion 42 and extends along each groove portion 42.

The trough 42 continues to a material flow inlet 44 formed in the side of the planar spiral 40. The material flow inlet 44 is a portion that receives the material supplied via the communication path 22 of the material supply portion 20.

When the planar spiral 40 is rotated, at least a part of the material supplied from the material inlet 44 is melted by heating by a heater 58 described later inside the groove 42, and the fluidity is improved. Then, the material flows toward the central portion 46 through the groove portions 42, is collected in the central portion 46, and is pushed out toward the communication holes 56 of the screw opposite portion 50 by the internal pressure generated therein.

As shown in fig. 3, the planar spiral 40 has three trough portions 42, three peak portions 43, and three material flow inlets 44. The number of the groove portions 42, the ridge portions 43, and the material inflow ports 44 provided in the planar spiral 40 is not limited to three. The planar spiral 40 may be provided with only one groove 42, or may be provided with two or more grooves 42. The number of the mountain portions 43 and the material inlets 44 may be equal to the number of the groove portions 42.

Fig. 4 is a schematic plan view showing the upper surface Ga side of the screw opposite portion 50. As described above, the upper surface Ga of the spiral opposite portion 50 faces the groove forming surface Fb of the planar spiral 40. Hereinafter, the upper surface Ga is also referred to as "screw-facing surface Ga".

A plurality of guide grooves 54 are formed in the screw-facing surface Ga. The guide groove 54 is connected to a communication hole 56 formed in the center of the screw facing surface Ga, and extends spirally from the communication hole 56 to the outer periphery. The plurality of guide grooves 54 have a function of guiding the molding material toward the communication hole 56. As described with reference to fig. 2, a heater 58 for heating the material is embedded in the screw opposite portion 50. The melting of the material in the modeling material generation unit 30 is achieved by the heating of the heater 58 and the rotation of the planar spiral 40. The molten material is pushed out to the flow path 65 of the ejection portion 60 via the communication hole 56 of the screw opposing portion 50 and guided to the nozzle 61. The material guided to the nozzle 61 is finally discharged from the opening 62.

As shown in fig. 2, in the molding unit 100, since the planar screw 40 having a small size in the Z direction is used, the occupied range of the path for melting at least a part of the material and guiding it to the nozzle 61 in the Z direction becomes small. In this way, in the molding unit 100, since the planar spiral 40 is used, the mechanism for producing the molding material is miniaturized. Further, by using the flat screw 40, the accuracy of ejection control of the molding material from the nozzle 61 is improved, and molding of the molded object in the first molding step and the second molding step, which will be described later, can be performed easily and efficiently.

In the molding unit 100, since the flat screw 40 is used, the molding material in a fluid state is simply fed under pressure to the nozzle 61. With this configuration, the ejection amount of the molding material from the opening 62 of the nozzle 61 can be controlled by controlling the number of rotations of the planar screw 40, and ejection control of the molding material from the opening 62 is facilitated. The "ejection amount of the molding material from the opening 62" refers to a flow rate of the molding material flowing out from the opening 62 of the nozzle 61.

Fig. 5 is a flowchart showing the contents of the three-dimensional modeling process in the present embodiment. First, in step S110, the control unit 90 acquires tool trajectory data for realizing the first molding process to the cutting process from a computer or a recording medium connected to the three-dimensional molding machine 10. The tool trajectory data is data indicating the scanning trajectory of the modeling unit 100, the cutting unit 99, and the moving mechanism 80 that moves the modeling table 81 when modeling the three-dimensional object OB. The shape data of the three-dimensional shaped object OB expressed in the STL format or the AMF format is converted into tool trajectory data by a limiter. Then, in step S120, the control unit 90 performs material generation control to control the rotation of the planar screw 40, thereby performing a material generation step of melting at least a part of the material to start the generation of the modeling material. The molding material is continuously produced while the first molding step and the second molding step, which will be described later, are performed. Thereafter, in steps S130 to S160, the first molding step, the first curing step, the second molding step, and the second curing step are performed in this order. The details of the first molding step, the first curing step, the second molding step, and the second curing step will be described later with reference to fig. 6 to 9. In the present embodiment, before the first molding step is performed, the temperature of the molding surface Ts is controlled by the temperature control heater 82 built in the molding table 81 so as to reach a temperature not exceeding the glass transition point of the molding material. By adjusting the temperature of the molding surface Ts, the adhesion between the three-dimensional object OB molded by the three-dimensional molding process and the molding surface Ts is improved. The temperature regulation of the moulding surface Ts is not necessary. In step S170, the control unit 90 controls the cutting unit 99 by executing the cutting control, and performs a cutting process of cutting at least a part of the three-dimensional object OB. By this cutting step, surface finishing of the three-dimensional object OB and the like can be performed.

Fig. 6 is a process diagram illustrating a first molding step in the present embodiment. In the first molding step, the control unit 90 performs the first molding control to discharge the molten molding material from the nozzle 61 to the molding surface Ts while changing the relative position of the nozzle 61 and the molding surface Ts, thereby molding the first section 110, the second section 120, and the third section 130 in which the molding material is laminated on the molding surface Ts. The first, second and third segments 110, 120, 130 are each separately contoured in a first direction parallel to the contour plane Ts. The first, second and third segments 110, 120 and 130 are molded by laminating a plurality of layers of molding materials upward in a second direction perpendicular to the molding plane Ts. The first direction of the present embodiment is the X direction, and the second direction is the Z direction. The second direction upward refers to a direction away from the molding surface Ts. The second direction upper side of the present embodiment is the + Z direction. In the present embodiment, first, the first stage 110 is molded by laminating ten layers of molding material. Then, the second stage 120 is molded by laminating ten layers of molding material at a position separated from the first stage 110 in the + X direction. Thereafter, the third segment 130 is molded by stacking ten layers of molding material at a position separated from the second segment 120 in the + X direction. In the present embodiment, the first, second, and third segments 110, 120, and 130 are shaped in such a manner that the cross-section of the first, second, and third segments 110, 120, and 130, which are cut along a plane parallel to the X-direction and parallel to the Z-direction, is a trapezoidal shape in which the base on the bottom surface side is longer than the upper edge on the upper surface side. In each segment 110, 120, 130, the "bottom surface" is the surface on the side of the moulding surface Ts. In each of the segments 110, 120, 130, the "upper surface" is a surface separated from the bottom surface toward the second direction, and is a surface on the opposite side from the bottom surface. "trapezoidal" means substantially trapezoidal in meaning in addition to a standard trapezoidal shape. The "substantially trapezoidal shape" includes, for example, a shape in which a part of the trapezoidal shape is curved, and a shape in which a part of the trapezoidal shape has irregularities or steps. In the present embodiment, the first, second, and third segments 110, 120, and 130 are shaped so that the widths in the Y direction are the same, respectively.

In the present embodiment, the first stage 110 has a first left side surface 111 as an end surface on the-X direction side and a first right side surface 112 as an end surface on the + X direction side. The second segment 120 has a second left side surface 121 as an end surface on the-X direction side and a second right side surface 122 as an end surface on the + X direction side. The third segment 130 has a third left side surface 131 as an end surface on the-X direction side and a third right side surface 132 as an end surface on the + X direction side. The first left side surface 111 and the third right side surface 132 are shaped to be perpendicular to the shaping surface Ts. The first right side 112 is spaced from the second section 120 as it moves away from the molding surface Ts in the Z direction and is inclined at an angle θ 12 with respect to the molding surface Ts. The second left side 121 diverges from the first segment 110 with distance from the molding surface Ts in the Z direction, and is inclined at an inclination angle θ 21 with respect to the molding surface Ts. The second right side 122 is spaced from the third section 130 as it moves away from the styling surface Ts in the Z direction, and is inclined at an angle θ 22 with respect to the styling surface Ts. The third left side 131 diverges from the second section 120 with distance from the molding surface Ts in the Z direction and is inclined at an inclination angle θ 31 with respect to the molding surface Ts. The inclination angles θ 12, θ 21, θ 22, and θ 31 are preferably set so that the side surfaces 112, 121, 122, and 131 inclined in a later step do not interfere with the nozzle 61. The inclination angles θ 12, θ 21, θ 22, and θ 31 are set to 60 ° or less, for example.

Fig. 7 is a process diagram illustrating a first curing step in the present embodiment. In the first curing step, the control section 90 performs first curing control to cure the first, second, and third stages 110, 120, and 130. In the present embodiment, ABS resin having thermoplasticity is used as the molding material, and thus, the first, second, and third stages 110, 120, and 130 are solidified by cooling the laminated molding material. In the present embodiment, the control unit 90 cools and solidifies the laminated molding material by leaving it as it is for a predetermined period of time. The three-dimensional modeling apparatus 10 may include a blower, and the stacked modeling materials may be cooled by the air blown by the blower.

Fig. 8 is a process diagram illustrating a second molding step in the present embodiment. In the second molding step, the control unit 90 performs the second molding control to discharge the molten molding material from the nozzle 61 toward the molding surface Ts while changing the relative position between the nozzle 61 and the molding surface Ts, thereby molding the fourth stage 140 in which the molding material is stacked between the first stage 110 and the second stage 120. The control section 90 molds the fifth stage 150, in which the molding material is laminated, between the second stage 120 and the third stage 130 in the same manner as the fourth stage 140. The fourth segment 140 includes a shape that continuously joins the first right side surface 112, which is the end surface on the second segment 120 side, of the first segment 110 and the second left side surface 121, which is the end surface on the first segment 110 side, of the second segment 120. The fifth segment 150 includes a shape that continuously joins the second right side surface 122 of the second segment 120, which is the end surface on the third segment 130 side, and the third left side surface 131 of the third segment 130, which is the end surface on the second segment 120 side. "continuously joined" when two portions of a three-dimensional object are the same width and height means that the portions are joined together at the same width and height. In addition, when the width and the height of two parts of the separated three-dimensional modeling object are different, the parts are connected together in a mode that the height and the width are gradually increased or decreased. In the present embodiment, the fourth segment 140 is molded by laminating ten layers of the molding material between the first segment 110 and the second segment 120, and the first segment 110 and the second segment 120 are joined together by the fourth segment 140. Thereafter, the fifth section 150 is molded by laminating ten layers of molding material between the second section 120 and the third section 130, and the second section 120 and the third section 130 are joined together by the fifth section 150. In the present embodiment, the fourth segment 140 and the fifth segment 150 are shaped such that the cross-sectional surfaces of the fourth segment 140 and the fifth segment 150, which are cut along the plane parallel to the X direction and the Z direction, are trapezoidal shapes having the bottom side on the bottom surface side shorter than the upper side on the upper surface side. In each segment 140, 150, the "bottom surface" is the surface on the side of the moulding surface Ts. In each segment 140, 150, the "upper surface" refers to the surface on the side opposite the bottom surface. In the present embodiment, the fourth and fifth segments 140 and 150 are shaped in the same manner in which the width in the Y direction is the same as the first, second, and third segments 110, 120, and 130, respectively.

In the present embodiment, the fourth stage 140 has a fourth left side surface 141 as an end surface on the-X direction side and a fourth right side surface 142 as an end surface on the + X direction side. The fifth stage 150 has a fifth left side face 151 as an end face on the-X direction side and a fifth right side face 152 as an end face on the + X direction side. The fourth segment 140 is shaped such that the fourth left side 141 meets the first right side 112 and the fourth right side 142 meets the second left side 121. The fifth section 150 is shaped in such a way that the fifth left side 151 meets the second right side 122 and the fifth right side 152 meets the third left side 131.

Fig. 9 is a process diagram showing a second curing step in the present embodiment. In the second curing step, the controller 90 performs second curing control to cure the fourth stage 140 and the fifth stage 150 in the same manner as in the first curing step. The three-dimensional object OB is molded through the first molding step to the second curing step. In this specification, the first stage 110 is sometimes referred to as a first portion, the second stage 120 formed to be separated from the first stage 110 in the first direction is sometimes referred to as a second portion, and the fourth stage 140 formed between the first stage 110 and the second stage 120 is sometimes referred to as a third portion. The second segment 120 may be referred to as a first portion, the third segment 130 formed separately from the second segment 120 in the first direction may be referred to as a second portion, and the fifth segment 150 formed between the second segment 120 and the third segment 130 may be referred to as a third portion.

Since the three-dimensional object OB is molded by laminating the molding material discharged from the nozzle 61 from the bottom surface side to the upper surface side, the molding material discharged from the nozzle 61 on the bottom surface side is cooled and solidified earlier than the molding material discharged from the nozzle 61 on the upper surface side. The modeling material shrinks upon curing. When the molding material on the upper surface side that is post-cured shrinks, the molding material on the bottom surface side that is pre-cured is pulled, and thus the three-dimensional object OB warps. The longer the length of the molding material once cured, the larger the shrinkage amount, and the larger the force with which the molding material on the bottom surface side is pulled by the molding material on the upper surface side. Therefore, the longer the length of the primary solidified modeling material is, the greater the warpage generated in the three-dimensional modeled object OB. In the present embodiment, in the first to fifth stages 110 to 150 constituting the three-dimensional object OB, the first to third stages 110 to 130 are first divided and molded by the first molding step shown in fig. 6, and the first to third stages 110 to 130 are cured by the first curing step shown in fig. 7. At this time, as shown by arrows in fig. 7, a small force causing warpage acts on each of the first segment 110 to the third segment 130. Due to the small force, small warpage is generated on the first segment 110 to the third segment 130, respectively. Thereafter, the fourth to fifth stages 140 to 150 are molded so as to fill the remaining portion of the three-dimensional object OB by the second molding step shown in fig. 8, and the fourth to fifth stages 140 to 150 are cured by the second curing step shown in fig. 9. At this time, as shown by arrows in fig. 9, a small force causing warpage acts on each of the fourth to fifth segments 140 to 150. Due to the small force, small warpage occurs on the fourth to fifth sections 140 to 150, respectively. That is, in the present embodiment, since the force causing warpage which acts on the entire three-dimensional object OB when the three-dimensional object OB is molded and cured at once is dispersed in each of the first stage 110 to the fifth stage 150, warpage of the entire three-dimensional object OB is small.

Fig. 10 is an explanatory diagram illustrating a warp state of the three-dimensional shaped object OB2 in the comparative example. The three-dimensional shaped object OB2 of the comparative example is the same size as the three-dimensional shaped object OB of the first embodiment. Unlike the three-dimensional object OB of the first embodiment, the three-dimensional object OB2 of the comparative example is not divided into the first to fifth stages 110 to 150, but is molded and cured all at once. When the three-dimensional object OB2 is cured, as shown by the arrow in fig. 10, the molding material on the bottom surface side that has been cured first is greatly pulled by the shrinkage of the molding material on the upper surface side that has been cured later, and a large force for warping acts, so that the three-dimensional object OB2 is greatly warped. Therefore, in the comparative example, the warp amount D of the entire three-dimensional shaped object OB2 is larger than that in the first embodiment.

According to the method for manufacturing the three-dimensional object OB of the present embodiment described above, the controller 90 molds the first stage 110, the second stage 120, and the third stage 130 separately in the X direction in the first molding step, and cures the separately molded stages 110, 120, and 130 in the first curing step. Thereafter, in the second shaping step, the controller 90 shapes the fourth segment 140 and the fifth segment 150 so that the segments 110, 120, and 130 that are separately shaped are connected to each other, and in the second curing step, the fourth segment 140 and the fifth segment 150 are cured to produce the three-dimensional shaped object OB. Therefore, warpage of the three-dimensional object OB can be suppressed as compared with the case where the three-dimensional object OB including the respective stages 110, 120, 130, 140, and 150 is molded and cured at one time.

In the present embodiment, the respective segments 110, 120, and 130 are molded such that, of the end surfaces of the first segment 110, the second segment 120, and the third segment 130 molded in the first molding step, the end surface that contacts the fourth segment 140 and the fifth segment 150 molded in the second molding step is inclined at an acute angle with respect to the molding surface Ts. Therefore, when the respective stages 140, 150 are molded in the second molding step, the nozzle 61 can be prevented from interfering with the respective stages 110, 120, 130 molded in the first molding step. In particular, in the present embodiment, since the respective segments 110, 120, and 130 molded in the first molding step are molded in a trapezoidal shape, the intervals between the respective segments 110, 120, and 130 can be ensured more reliably. Therefore, in the second molding step, the nozzle 61 can be further prevented from interfering with the stages 110, 120, and 130.

In the present embodiment, in the cutting step, the three-dimensional object OB is processed by the cutting unit 99. Therefore, a three-dimensional shaped object can be produced with high dimensional accuracy.

In addition, in the present embodiment, a conversion step of melting the material into the molding material by the flat spiral 40 is provided. For this purpose, the molten material is stacked by the molding unit 100 having the small flat spiral 40. Therefore, the three-dimensional object OB can be produced by using the small three-dimensional modeling apparatus 10.

In the present embodiment, a material of granular ABS resin is used, but as the material used in the modeling unit 100, for example, a material that models a three-dimensional modeled object using various materials such as a material having thermoplastic properties, a metal material, and a ceramic material as a main material may be used. Here, the "main material" means a material that forms the center of the shape of the shaped object, and means a material that occupies a content of 50% by weight or more in the three-dimensional shaped object. The molding material includes a material obtained by melting a main material in a single body form and a material obtained by melting a part of components contained together with the main material to form a paste.

In the case of using a material having thermoplasticity as the main material, the molding material is generated by plasticizing the material in the molding material generating section 30. "plasticizing" refers to melting a material having thermoplastic properties by heating.

As the material having thermoplasticity, for example, any one of the following thermoplastic resin materials 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 resins (PP), polyethylene resins (PE), polyoxymethylene resins (POM), polyvinyl chloride resins (PVC), polyamide resins (PA), acrylonitrile-butadiene-styrene resins (ABS), polylactic acid resins (PLA), polyphenylene sulfide resins (PPs), polyether ether ketone (PEEK), Polycarbonates (PC), modified polyphenylene ethers, polybutylene terephthalate, polyethylene terephthalate, and the like; engineering plastics such as polysulfone, polyethersulfone, polyphenylene sulfide, polyarylate, polyimide, polyamideimide, polyetherimide and polyetheretherketone.

The thermoplastic material may contain additives such as wax, flame retardant, antioxidant, and heat stabilizer in addition to pigments, metals, and ceramics. The thermoplastic material is plasticized by the rotation of the planar screw 40 and the heating of the heater 58 in the molding material producing section 30, and is converted into a molten state. The molding material thus produced is solidified by a temperature decrease after being discharged from the nozzle 61.

The material desirably having thermoplasticity is heated to above its glass transition point to be ejected from the nozzle 61 in a completely melted state. For example, the glass transition point of the ABS resin is about 120 ℃ and desirably about 200 ℃ when ejected from the nozzle 61. In order to eject the molding material in a high temperature state, a heater may be provided around the nozzle 61.

In the molding unit 100, for example, the following metal material may be used as a main material instead of the above-described material having thermoplasticity. In this case, it is desirable that a component melted at the time of producing the molding material is mixed with a powder material obtained by forming a metal material described below into a powder, and the mixture is fed into the molding material producing section 30.

< example of Metal Material >

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 modeling unit 100, a ceramic material can be used as a main material instead of the above-described metal material. As the ceramic material, for example, oxide ceramics such as silica, titania, alumina, zirconia, and the like; non-oxide ceramics such as aluminum nitride, and the like. When the metal material or the ceramic material as described above is used as the main material, the molding material disposed on the molding table 81 may be solidified by, for example, irradiation with a laser or sintering with warm air.

The metal material and the ceramic material powder 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. Further, for example, the powder material of the metal material or the ceramic material may be coated with the thermoplastic resin as exemplified above or another thermoplastic resin. In this case, the thermoplastic resin may be melted in the molding material generating section 30 to exhibit fluidity.

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 one selected from the following, or two or more selected from the following may be used in combination.

< example of 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, γ -picoline and 2, 6-lutidine; tetraalkylammonium acetate (e.g., tetrabutylammonium acetate), butyl carbitol acetate, and other ionic liquids.

Further, a binder such as the following may be added to the powder material of the metal material or the ceramic material charged into the material supply portion 20.

< example of adhesive >

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

B. Second embodiment

Fig. 11 is a flowchart showing the contents of the three-dimensional modeling process in the second embodiment. The second embodiment is different from the first embodiment in that a first reheating step of step S145 is provided between the first curing step of step S140 and the second molding step of step S150. The rest is the same as in the first embodiment.

Fig. 12 is a process diagram showing a first reheating step in the second embodiment. In the first reheating step, the controller 90 performs first reheating control such that, of the end surfaces of the first stage 110, the second stage 120, and the third stage 130 solidified in the first solidification step in the X direction, the end surfaces that are in contact with the fourth stage 140 or the fifth stage 150 in the second molding step shown in fig. 8, that is, the first right side surface 112, the second left side surface 121, the second right side surface 122, and the third left side surface 131 are heated by a heater or the like to remelt at least a part of the molding material. Thereafter, the controller 90 performs the second molding step while the molding material on the side surfaces 112, 121, 122, and 131 is molten.

According to the method for producing the three-dimensional object OB of this embodiment, the adhesion between the fourth stage 140 and the first and second stages 110 and 120, and the adhesion between the fifth stage 150 and the second and third stages 120 and 130 can be improved.

C. Third embodiment

Fig. 13 is a flowchart showing the contents of the three-dimensional modeling process in the third embodiment. In the third embodiment, the fourth and fifth stages 140B and 150B molded in the second molding step of step S150 are different from the first embodiment in terms of the form. In addition, unlike the first embodiment, the third molding step of step S161 and the third curing step of step S162 are provided after the second curing step of step S160. The rest is the same as in the first embodiment.

Fig. 14 is a process diagram showing a second molding step for producing the lower layer 210 of the three-dimensional object OB according to the third embodiment. The three-dimensional object OB of the present embodiment is composed of a lower layer 210 formed on a forming surface Ts and an upper layer 220 formed on the lower layer 210. The fourth stage 140B molded in the second molding step of the present embodiment has a configuration in which the fourth stage 140 of the first embodiment is further stacked vertically symmetrically on the fourth stage 140 of the first embodiment. The fifth stage 150B molded in the second molding step of the present embodiment has a configuration in which the fifth stage 150 of the first embodiment is further stacked vertically symmetrically above the fifth stage 150 of the first embodiment. That is, in the second forming step of the present embodiment, the fourth segment 140B and the fifth segment 150B are formed such that the cross-sectional surfaces of the fourth segment 140B and the fifth segment 150B, which are cut along the plane parallel to the X direction and the Z direction, are respectively formed in a hexagonal shape. "hexagonal" in addition to a standard hexagonal shape also includes substantially hexagonal shapes in meaning. The term "substantially hexagonal" includes, for example, a shape in which a part of a hexagon is curved, a shape in which a part of a hexagon has irregularities, and a step. In fig. 14, a shape of the fourth segment 140B that continuously joins together the end surface on the second segment 120 side of the first segment 110 and the end surface on the first segment 110 side of the second segment 120 is shown by a broken line. Further, a shape of the fifth segment 150B in which the end surface on the third segment 130 side of the second segment 120 and the end surface on the second segment 120 side of the third segment 130 are continuously joined together is shown by a broken line. The upper portion of the fourth segment 140B and the upper portion of the fifth segment 150B are part of the upper deck 220.

Fig. 15 is a process diagram showing a third shaping step for producing the upper layer 220 of the three-dimensional shaped object OB according to the third embodiment. In the present embodiment, after the second curing step, the third molding step and the third curing step are performed to fabricate the sixth stage 160, the seventh stage 170, and the eighth stage 180, which are part of the upper layer 220, on the cured first stage 110, the second stage 120, and the third stage 130. In the third molding step, the control unit 90 performs third molding control to discharge the molten molding material from the nozzle 61 toward the molding surface Ts while changing the relative position of the nozzle 61 and the molding surface Ts, thereby molding the sixth stage 160 having a configuration in which the first stage 110 of the lower layer 210 is vertically symmetrically stacked on the first stage 110 of the lower layer 210. Similarly to the sixth segment 160, the control unit 90 shapes the seventh segment 170 having a configuration in which the second segment 120 of the lower layer 210 is vertically symmetrically stacked on the second segment 120 of the lower layer 210, and shapes the eighth segment 180 having a configuration in which the third segment 130 of the lower layer 210 is vertically symmetrically stacked on the third segment 130 of the lower layer 210. After that, the control section 90 executes third curing control similar to the first curing control, thereby curing the sixth, seventh and eighth stages 160, 170 and 180.

According to the method for producing the three-dimensional object OB of the present embodiment described above, since the second molding step and the second curing step are performed to mold a part of the upper layer 220 of the three-dimensional object OB when molding the lower layer 210 of the three-dimensional object OB, a part of the step for molding the upper layer 220 of the three-dimensional object OB can be omitted. Therefore, productivity of the three-dimensional shaped object OB can be improved.

In the present embodiment, first, the fourth stage 140B and the fifth stage 150B, which are part of the upper layer 220 of the three-dimensional object OB, are molded in the second molding step, and then cured in the second curing step. Thereafter, in the third shaping step, the sixth section 160, the seventh section 170, and the eighth section 180, which are the remaining portions of the upper layer 220 of the three-dimensional shaped object OB, are shaped so as to be separated from each other with the fourth section 140B and the fifth section 150B interposed therebetween, and are cured in the third curing step. Therefore, warpage is suppressed also in the upper layer 220 of the three-dimensional shaped object OB.

D. Fourth embodiment

Fig. 16 is a flowchart showing the contents of the three-dimensional modeling process in the fourth embodiment. The fourth embodiment is different from the first embodiment in that, after the cutting step of step S170, it is determined whether or not the three-dimensional object OB has been formed and a second reheating step is provided in step S180. The rest is the same as in the first embodiment.

In step S180, the control unit 90 determines whether the three-dimensional object OB has been shaped. The tool trajectory data can be used to determine whether the three-dimensional object OB is completely molded. For example, by measuring the three-dimensional object OB using a three-dimensional digitizer to create three-dimensional shape data and comparing the three-dimensional shape data with the shape data used when generating the tool trajectory data, it is possible to determine whether or not the three-dimensional object OB has been shaped. When it is not determined in step S180 that the three-dimensional object OB has been formed, the controller 90 performs the second reheating process in step S190, and thereafter repeats the process from step S130 to step S150 to form the upper layer 220, which is the remaining portion of the three-dimensional object OB excluding the lower layer 210, on the lower layer 210 of the three-dimensional object OB formed of the first stage 110 to the fifth stage 150. On the other hand, when it is determined in step S180 that the three-dimensional object OB is completely formed, the control unit 90 ends the three-dimensional forming process.

Fig. 17 is a process diagram illustrating a second reheating step in the fourth embodiment. In the second reheating step, the controller 90 performs second reheating control to heat the first upper surface 113 of the solidified first stage 110, the second upper surface 123 of the second stage 120, the third upper surface 133 of the third stage 130, the fourth upper surface 143 of the fourth stage 140, and the fifth upper surface 153 of the fifth stage 150 by a heater or the like, thereby re-melting at least a part of the modeling material.

Fig. 18 is a process diagram showing a first molding step for producing the upper layer 220 of the three-dimensional object OB according to the fourth embodiment. After the second reheating process, the controller 90 performs a first molding process for manufacturing the upper layer 220 in a state where the molding material is melted on the first upper surface 113 of the first stage 110, the second upper surface 123 of the second stage 120, the third upper surface 133 of the third stage 130, the fourth upper surface 143 of the fourth stage 140, and the fifth upper surface 153 of the fifth stage 150 of the lower layer 210. The first molding step for forming upper layer 220 has the same contents as those of the first molding step for forming lower layer 210.

According to the method of manufacturing the three-dimensional object OB of this embodiment, since the upper layer 220 is molded in a state where the molding material is melted on the upper surfaces 113, 123, 133, 143, and 153 of the lower layer 210 of the three-dimensional object OB, the adhesion between the lower layer 210 and the upper layer 220 can be improved.

The three-dimensional modeling process of the present embodiment and the three-dimensional modeling process of the third embodiment may be combined. Specifically, the control unit 90 may perform the second reheating step after step S160 in fig. 13. Further, the three-dimensional modeling process of the present embodiment and the three-dimensional modeling process of the second embodiment may be combined. Specifically, the control unit 90 may perform the first reheating step between step S140 and step S150 in fig. 16.

E. Other embodiments

(E1) In the method of manufacturing the three-dimensional shaped object OB according to each of the above embodiments, the first right side surface 112 of the first stage 110, the second left side surface 121 and the second right side surface 122 of the second stage 120, and the third left side surface 131 of the third stage 130, which are shaped in the first shaping step, are inclined with respect to the shaping surface Ts. In contrast, the side surfaces 112, 121, 122, and 131 molded in the first molding step may be perpendicular to the molding surface Ts. That is, the cross-sectional surfaces of the first, second, and third segments 110, 120, and 130, which are cut along a plane parallel to the X-direction and parallel to the Z-direction, may have a rectangular shape. "rectangular" means not only a standard rectangle but also a substantially rectangular shape in meaning. The term "substantially rectangular" includes a shape in which a part of a rectangle is curved, and a shape in which a part of a rectangle has irregularities or steps. In this case, the heights of the first stage 110, the second stage 120, and the third stage 130 are preferably such that they do not interfere with the nozzle 61 in the second molding step, even if the orientation of the nozzle 61 is not changed.

(E2) In the method for producing the three-dimensional shaped object OB according to each of the above embodiments, the first segment 110, the second segment 120, and the third segment 130 shaped in the first shaping step have a polygonal shape having at least four corners, the cross-section of which is cut along a plane parallel to the X direction and parallel to the Z direction, and the cross-section of which is cut along a plane parallel to the X direction and parallel to the Z direction, of the fourth segment 140 and the fifth segment 150 shaped in the second shaping step. On the other hand, the cross-sectional surface of the first, second, and third segments 110, 120, and 130 molded in the first molding step, which is cut along a plane parallel to the X direction and parallel to the Z direction, may have a triangular shape. "triangle" means not only a standard triangle but also a substantially triangle in meaning. The term "substantially triangular" includes a shape in which a part of a triangle is curved, and a shape in which a part of a triangle has irregularities and steps. The cross-sectional surfaces of the fourth and fifth segments 140 and 150 molded in the second molding step, which are cut along the planes parallel to the X direction and the Z direction, may be triangular.

(E3) In the second shaping step of the third embodiment, the fourth stage 140B and the fifth stage 150B are shaped such that a cross-sectional surface cut along a plane parallel to the X direction and parallel to the Z direction has a hexagonal shape. In contrast, the cross-sectional surfaces of the fourth segment 140B and the fifth segment 150B cut along a plane parallel to the X direction and the Z direction may not be hexagonal, and for example, as shown in fig. 19, the cross-sectional surfaces of the fourth segment 140B and the fifth segment 150B cut along a plane parallel to the X direction and the Z direction may be rhombic. "diamond" in its meaning includes substantially diamond shapes in addition to standard diamond shapes. The "substantially rhombic shape" includes, for example, a shape in which a part of the rhombic shape is curved, and a shape in which a part of the rhombic shape has irregularities and steps. In fig. 19, a shape of the fourth segment 140B that continuously joins together the end face of the first segment 110 and the end face of the second segment 120, and a shape of the fifth segment 150B that continuously joins together the end face of the second segment 120 and the end face of the third segment 130 are shown by broken lines. The cross-sectional surfaces of the fourth segment 140B and the fifth segment 150B, which are cut along a plane parallel to the X direction and parallel to the Z direction, may be pentagonal or polygonal. "polygonal" means not only a standard polygonal shape but also a substantially polygonal shape in meaning. The term "substantially polygonal" includes, for example, a shape in which a part of a polygon is curved, and a shape in which a part of a polygon has irregularities or steps. In this case, the fourth segment 140B is shaped such that at least one vertex of the polygon is located further away from the molding surface Ts than the respective upper surfaces of the first segment 110 and the second segment 120. The fifth segment 150B is shaped such that at least one vertex of the polygon is located further from the molding surface Ts than the respective upper surfaces of the second segment 120 and the third segment 130.

(E4) In the method of manufacturing the three-dimensional object OB according to each of the above embodiments, the three-dimensional object OB is manufactured by laminating the molding materials having the thermoplastic properties and cooling and solidifying the laminated molding materials. On the other hand, the method of manufacturing the three-dimensional shaped object OB may be a laser sintering method. In this case, a molding material having metal powder as a main material may be laminated, and the laminated molding material may be irradiated with laser light to cure the three-dimensional object OB.

(E5) In the method for producing the three-dimensional object OB according to each of the above embodiments, the second curing step is followed by the cutting step. In contrast, the cutting step may be performed between the first curing step and the second molding step. Further, the cutting step may not be performed.

(E6) In the three-dimensional modeling apparatus 10 according to each of the above embodiments, the modeling material generating unit 30 includes the planar spiral 40. In contrast, the modeling material generating unit 30 may include a straight spiral that is longer than the planar spiral 40 in the Z direction, instead of the planar spiral 40. The three-dimensional molding machine 10 may be of a normal FDM system (fused deposition modeling system) that does not include the planar screw 40 or the inline screw. That is, the three-dimensional modeling apparatus 10 may be configured as follows: the molding material is discharged from the nozzle by melting the filament fed from the bobbin into the nozzle by a heater provided in the nozzle.

(E7) In the three-dimensional modeling apparatus 10 according to each of the above embodiments, the first stage 110, the second stage 120, the third stage 130, the fourth stage 140, and the fifth stage 150 are arranged on a straight line along the X direction. On the other hand, the first segment 110, the second segment 120, and the third segment 130 may be arranged in a staggered manner, and the fourth segment 140 and the fifth segment 150 may be arranged to connect therebetween. In this case, between the first stage 110 and the second stage 120, a direction from the first stage 110 toward the second stage 120, that is, a longitudinal direction of the fourth stage 140 is a first direction. Between the second segment 120 and the third segment 130, a direction from the second segment 120 to the third segment 130, that is, a longitudinal direction of the fifth segment 150 is a first direction. For example, when the three-dimensional object OB molded according to the shape data has a cylindrical shape having a central axis perpendicular to the molding surface Ts, the segments 110, 120, 130, 140, and 150 may be arranged along the circumferential direction of the cylindrical shape. In this case, the circumferential direction of the cylindrical shape is the first direction. That is, the first direction is a direction in which the molded three-dimensional molded object OB extends.

F. Other ways

The present invention is not limited to the above embodiments, and can be implemented in various forms without departing from the spirit thereof. For example, the present invention can also be realized by the following aspects. In order to solve some or all of the technical problems of the present invention or achieve some or all of the effects of the present invention, the technical features of the above-described embodiments corresponding to the technical features of the aspects described below may be appropriately replaced or combined. Note that, as long as the technical features are not described as essential features in the present specification, the technical features may be appropriately deleted.

(1) According to one aspect of the present invention, a method of manufacturing a three-dimensional shaped object is provided. The method for producing a three-dimensional shaped object comprises: a first molding step of ejecting a molding material from a nozzle onto a molding surface of a molding table to mold a first portion and a second portion separately from each other in a first direction parallel to the molding surface; a curing step of curing the first part and the second part; and a second molding step of, after the curing step, discharging a molding material from the nozzle between the first portion and the second portion to mold a third portion having a shape in which an end surface of the first portion in the first direction and an end surface of the second portion in the first direction are continuously joined together.

According to the method of manufacturing a three-dimensional shaped object of this aspect, after the first part and the second part constituting the three-dimensional shaped object are shaped and cured separately, the third part is shaped and cured so as to be joined together. Therefore, compared with molding and curing the three-dimensional object including the first portion, the second portion, and the third portion at once, warpage of the three-dimensional object can be suppressed.

(2) In the method of manufacturing a three-dimensional shaped object according to the above aspect, an end surface of the first portion and an end surface of the second portion that contact the third portion may be inclined so as to be apart from each other as they are separated from the shaping surface in a second direction perpendicular to the shaping surface.

According to the method of producing a three-dimensional shaped object of this aspect, in the second shaping step, the nozzle can be prevented from interfering with the first portion and the second portion.

(3) In the method of manufacturing a three-dimensional shaped object according to the above aspect, the cut surfaces of the first portion and the second portion cut along a plane parallel to the first direction and parallel to the second direction may each have a trapezoidal shape with a longer bottom side than an upper side.

According to the method of producing a three-dimensional shaped object of this aspect, since the distance between the first portion and the second portion can be secured, the nozzle can be further suppressed from interfering with the first portion and the second portion in the second shaping step.

(4) In the method of manufacturing a three-dimensional shaped object according to the above aspect, the cut surface of the third portion cut along a plane parallel to the first direction and parallel to the second direction may be a polygon having four or more sides including a first side contacting an end surface of the first portion and a second side contacting an end surface of the second portion, and at least one vertex of the polygon may be located farther from the shaping surface than a surface of the first portion and the second portion on a side separated from the shaping surface in the second direction.

According to the method of manufacturing a three-dimensional shaped object of this aspect, since the portion of the upper layer of the three-dimensional shaped object located on the side farther from the shaping surface than the first portion and the second portion is shaped by the second shaping step and the second curing step performed when shaping the lower layer of the three-dimensional shaped object, at least a part of the second shaping step and the second curing step can be omitted when shaping the upper layer of the three-dimensional shaped object. Therefore, productivity of the three-dimensional shaped object can be improved.

(5) In the method of producing a three-dimensional shaped object according to the above aspect, the polygon may be a hexagon.

According to the method for producing a three-dimensional shaped object of this aspect, productivity of the three-dimensional shaped object can be more effectively improved.

(6) In the method for producing a three-dimensional shaped object according to the above aspect, a first reheating step may be provided between the curing step and the second shaping step, and at least one of an end surface of the first portion and an end surface of the second portion that are in contact with the third portion may be heated in the first reheating step.

According to the method for producing a three-dimensional shaped object of this aspect, the adhesion of the third portion to the first portion and the second portion can be improved.

(7) The method of manufacturing a three-dimensional shaped object according to the above aspect may further include a second reheating step of heating a surface of at least one of the first portion, the second portion, and the third portion on a side separated from the shaping surface side in a direction perpendicular to a second direction of the shaping surface after the third portion is solidified, and may further perform shaping of a remaining portion of the three-dimensional shaped object other than the first portion, the second portion, and the third portion on a surface of the first portion, the second portion, and the third portion on a side separated from the shaping surface side in the second direction after the second reheating step.

According to the method of producing a three-dimensional shaped object of this aspect, the adhesion between the lower layer of the three-dimensional shaped object shaped first in the second reheating step and the upper layer of the three-dimensional shaped object shaped after the second reheating step is improved.

(8) The method of manufacturing a three-dimensional shaped object according to the above aspect may further include a third shaping step of shaping a portion of the first portion that is in contact with the third portion so as to be spaced apart from each other on a surface of the first portion that is separated from the shaping surface in the second direction and on a surface of the second portion that is separated from the shaping surface in the second direction, after the third portion is solidified.

According to the method of producing a three-dimensional shaped object of this aspect, after the third portion that is a part of the upper layer of the three-dimensional shaped object is shaped and solidified, the remaining portion of the upper layer of the three-dimensional shaped object is shaped so as to be separated through the third portion. Therefore, warpage is also suppressed in the upper layer of the three-dimensional shaped object.

(9) The method of manufacturing a three-dimensional shaped object according to the above aspect may further include a step of cutting at least a part of the solidified first portion, second portion, and third portion after the third portion is solidified.

According to the method of manufacturing a three-dimensional shaped object of this aspect, the three-dimensional shaped object is processed by cutting. Therefore, the three-dimensional shaped object can be produced with high dimensional accuracy.

(10) The method of producing a three-dimensional shaped object according to the above aspect may further include a material melting step of melting a material into the shaped material by a rotating planar screw.

According to the method of producing a three-dimensional shaped object of this aspect, the shaping material is produced by a small-sized planar spiral. Therefore, the three-dimensional object can be molded by using a small three-dimensional molding apparatus.

The present invention can be realized in various aspects other than the method for producing a three-dimensional shaped object. For example, the present invention can be realized by a three-dimensional modeling apparatus, a method for controlling a three-dimensional modeling apparatus, a computer program for implementing the control method, a non-transitory recording medium on which the computer program is recorded, and the like.