JP7347030B2 - Three-dimensional object manufacturing device and three-dimensional object manufacturing method - Google Patents

Description

The present invention relates to an apparatus for manufacturing a three-dimensional structure and a method for manufacturing a three-dimensional structure.

Three-dimensional modeling methods using the inkjet method include the Material Jet method (MJ method), in which a photocurable resin is ejected from an inkjet head, and the Binder Jet method, in which an ink serving as a crosslinking agent is ejected from an inkjet head onto a modeling area on a thin layered powder surface. (BJ method), High Speed Sintering method (HSS method) in which ink containing a radiation absorber is ejected from an inkjet head onto the modeling area on a thin layer of powder, and radiant energy is applied to melt and solidify the powder. etc. are already known.

In the inkjet method, droplets ejected from each nozzle of the head become a mist that floats in the air, and when that mist adheres to the nozzle surface, it becomes dirty, reducing the amount of droplets ejected, and Also, ejection failure such as droplets not being ejected may occur. Alternatively, in the case of a nozzle that ejects infrequently, droplets within the nozzle may thicken, resulting in ejection failure. If such ejection failure occurs during three-dimensional modeling, printing quality defects such as insufficient strength will occur. In addition, as a method to eliminate this quality defect, a method of shifting the head in the nozzle row direction (sub-scanning direction) has been disclosed, but if an ejection defect occurs at the same pitch as the pitch to be shifted, Quality defects cannot be resolved. Further, a method of discharging in parts has been disclosed (see, for example, Patent Document 1), but there is a problem in that the printing speed is significantly reduced.

An object of the present invention is to provide a manufacturing apparatus for a three-dimensional object that can suppress a decline in modeling quality even when an ejection failure occurs while suppressing a decline in modeling speed.

The three-dimensional object manufacturing apparatus of the present invention as a means for solving the above problems includes:
A three-dimensional object manufacturing device that manufactures a three-dimensional object by laminating modeling layers formed using ink,
a head having a nozzle row in which a plurality of nozzles for ejecting the ink are arranged side by side in the sub-scanning direction;
main scanning moving means for moving the head in a main scanning direction that is a direction perpendicular to the nozzle row;
sub-scanning moving means for moving the head in the sub-scanning direction;
a support that supports the modeling layer;
When the head is moved above the support and the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the modeling layer or its precursor layer, the n-th modeling layer or a line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer; The nozzle array when the ink is ejected from at least one of the plurality of nozzles of the nozzle array toward the n+1-th modeling layer or its precursor layer laminated on the modeling layer or its precursor layer. head movement control means for controlling the movement of the head so that when the locus of movement of the center point of the head is represented by a line (line n+1), the line n and the line n+1 do not overlap and are not parallel; ,
It is characterized by having the following.

According to the present invention, it is possible to provide a manufacturing apparatus for a three-dimensional object that can suppress a decrease in modeling quality even when a discharge failure occurs while suppressing a decrease in modeling speed.

FIG. 1 is a schematic plan view of an embodiment of a three-dimensional structure manufacturing apparatus of the present invention. FIG. 2 is a schematic side view showing a modeling section in an embodiment of the three-dimensional object manufacturing apparatus of the present invention. FIG. 3 is a block diagram showing an example of the configuration of a control section in an embodiment of the three-dimensional object manufacturing apparatus of the present invention. FIG. 4A is a schematic diagram showing an example of the flow of modeling a three-dimensional object (Part 1). FIG. 4B is a schematic diagram showing an example of the flow of modeling a three-dimensional object (part 2). FIG. 4C is a schematic diagram showing an example of the flow of modeling a three-dimensional object (part 3). FIG. 4D is a schematic diagram showing an example of the flow of modeling a three-dimensional structure (Part 4). FIG. 4E is a schematic diagram showing an example of the flow of modeling a three-dimensional object (Part 5). FIG. 5 is a schematic explanatory diagram for explaining the state of modeling by the head unit. FIG. 6 is a schematic explanatory diagram for explaining problems caused by ejection failure. FIG. 7A is a schematic diagram of an example of trying to eliminate quality defects due to ejection defects. FIG. 7B is a schematic diagram for explaining the locus of the center point of the nozzle array in FIG. 7A. FIG. 8 is a schematic explanatory diagram for explaining problems caused by ejection failure. FIG. 9A is a schematic diagram of an example of suppressing deterioration in modeling quality due to ejection failure according to the present invention. FIG. 9B is a schematic diagram for explaining the locus of the center point of the nozzle array in FIG. 9A. FIG. 10 is a schematic diagram of another example of suppressing deterioration in modeling quality due to ejection failure according to the present invention. FIG. 11 is a schematic explanatory diagram for explaining an example of the operating direction of the head unit. FIG. 12 is a schematic explanatory diagram for explaining another example of the operating direction of the head unit.

(Three-dimensional object manufacturing device, three-dimensional object manufacturing method)
The manufacturing device for a three-dimensional molded object (three-dimensional molded object) of the present invention is a three-dimensional molded object manufacturing device that manufactures a three-dimensional molded object by laminating modeling layers formed using ink.
The method for manufacturing a three-dimensional object of the present invention is a method for manufacturing a three-dimensional object, in which a three-dimensional object is manufactured by laminating modeling layers formed using ink.
The apparatus for manufacturing a three-dimensional object has at least a head, a main scanning movement means, a sub-scanning movement means, a support, and a head movement control means, and further includes a powder layer forming means, a radiation It has other means such as energy imparting means.
The method for manufacturing a three-dimensional object uses at least a head, a main scanning moving means, a sub scanning moving means, and a support, and further uses other means as necessary.
The method for manufacturing the three-dimensional structure includes, for example, a powder layer forming step and a radiant energy applying step.

The head movement control means moves the head above the support to eject the ink from at least one of the plurality of nozzles in the nozzle array toward the modeling layer or its precursor layer. A line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the n-th modeling layer or its precursor layer. The ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the n+1-th building layer or its precursor layer laminated on the n-th building layer or its precursor layer. When the trajectory of the movement of the center point of the nozzle row is represented by a line (line n+1), the movement of the head is controlled so that the line n and the line n+1 do not overlap or are parallel Control.

Then, for example, the movement of the head is repeatedly controlled by the head movement control means, the modeling layers are stacked, and a three-dimensional object is manufactured.

There are no particular restrictions on the method of three-dimensional modeling to which the manufacturing device and method of manufacturing a three-dimensional modeling device of the present invention are applied, and can be appropriately selected depending on the purpose. For example, Material Jet method (MJ method), Examples include the Binder Jet method (BJ method) and the High Speed Sintering method (HSS method).

The ink ejection in the manufacturing apparatus and manufacturing method of the three-dimensional modeling apparatus of the present invention is a so-called inkjet method.

Here, the building layer or its precursor layer when the head is moved above the support and ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the building layer or its precursor layer, n When the th modeling layer or its precursor layer and the n+1th modeling layer or its precursor layer are both modeling layers, the three-dimensional modeling method is, for example, the Material Jet method (MJ method), and the model material and Ink for forming the model material and the support material is ejected onto the modeling layer made of the support material.
On the other hand, when the head is moved above the support and ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the modeling layer or its precursor layer, the n-th When the modeling layer or its precursor layer and the n+1-th modeling layer or its precursor layer are both precursor layers of the modeling layer, the three-dimensional modeling method is, for example, the Binder Jet method (BJ method) or the High This is a speed sintering method, and an ink containing a crosslinking agent or an ink containing a radiant energy absorber is ejected onto a precursor layer that is a powder layer containing powder.

<Head>
The head has a nozzle row in which a plurality of nozzles for ejecting ink are arranged side by side in the sub-scanning direction.
The head ejects ink from nozzles.
In the head, the shape and structure of the nozzle are not particularly limited and can be appropriately selected depending on the purpose. For example, the nozzle may be a through hole formed in a surface constituting the head.

There is no particular restriction on the size of the ejection opening (for example, a through hole formed in a surface constituting the head) in the nozzle, and it can be appropriately selected depending on the purpose.
The number of nozzles in the nozzle row is not particularly limited and can be selected as appropriate depending on the purpose.
In the head, the number of nozzle rows may be one row or multiple rows.

The head is not particularly limited and can be appropriately selected depending on the purpose, and includes, for example, a piezoelectric element head, a thermal expansion head, and the like.

In the case of the Material Jet method (MJ method), for example, the head has two nozzle rows, and ink is ejected as a model material from the nozzles of one nozzle row, and ink is ejected as a support material from the nozzles of the other nozzle row. of ink is ejected.

<Main scanning movement means>
The main scanning moving means is not particularly limited as long as it moves the head in the main scanning direction, which is a direction perpendicular to the nozzle array, and can be selected as appropriate depending on the purpose. Examples include shaft actuators.
The movement of the head in the main scanning direction is usually a reciprocating movement.

<Sub-scanning means>
The sub-scanning means is not particularly limited as long as it is a means for moving the head in the sub-scanning direction, and can be appropriately selected depending on the purpose. Examples thereof include a motor, a single-axis actuator, and the like.

<Support>
As long as the support can support the modeling layer or its precursor layer, its size, shape, structure, and material are not particularly limited and can be appropriately selected depending on the purpose. Examples include the base plate in the device shown in FIG. 1 of Japanese Patent No. 328106.
The surface of the support, that is, the mounting surface on which the modeling layer is placed, may be, for example, a smooth surface, a rough surface, a flat surface, or a curved surface. There may be.

<Head movement control means>
The head movement control means moves the head above the support to eject ink from at least one of the plurality of nozzles in the nozzle row toward the building layer or its precursor layer. Or, the locus of the center point of the nozzle row when ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer is represented by a line (line n), and the trajectory of the center point of the nozzle row is represented by a line (line n), and A line represents the locus of movement of the center point of the nozzle row when ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the n+1-th modeling layer laminated on the body layer or its precursor layer. When represented by (line n+1), the movement of the head is controlled so that line n and line n+1 do not overlap and are not parallel. Here, n is a positive integer.
When a discharge failure occurs in the nozzle, as shown in FIGS. 6 and 8, which will be described later, streaks due to the discharge failure occur, the fixing force is insufficient at the position of the streaks, and the resulting three-dimensional object lacks strength.
On the other hand, in the present invention, by controlling the movement of the head as described above by the head movement control means, even if a nozzle discharge failure occurs, the same two-layer There will be no streaks due to non-ejection in the column. Furthermore, even if the lines of non-ejection intersect, there is no part where the non-ejection continues in the thickness direction of the modeling layer other than the point where the lines intersect. Therefore, insufficient strength of the obtained three-dimensional structure can be prevented.
Furthermore, regarding the printing speed, although the printing speed is slightly lower than scanning only in the main scanning direction, the printing speed is faster than the case of dividing discharge as in the invention described in JP 2017-105141A, and It is possible to prevent the speed from decreasing.

The movement of the head by the head movement means when controlling the movement of the head so that line n and line n+1 do not overlap and are not parallel is performed using a main scanning movement means and a sub-scanning movement means. .

The head movement control means may move the head so that line n and line n+1 intersect.

The head movement control means may control the movement of the head so that when the line n is reversed by 180 degrees about the main scanning direction, the reversed line n and the line n+1 become parallel. In that case, as shown in FIGS. 11 and 12, which will be described later, the head is moved so that line n and line n+1 intersect.
There is no particular limit to the intersection angle between line n and line n+1, and it can be selected as appropriate depending on the range in which ink is to be ejected. The sum (A+B) of the intersection angle A (acute angle) between the line n+1 and the main scanning direction and the intersection angle B (acute angle) between the line n+1 and the main scanning direction is preferably 90° or less, and preferably 60° or less. is more preferable. The lower limit of the sum (A+B) is not particularly limited and can be selected as appropriate depending on the purpose, for example, it may be greater than 0°, it may be greater than 10°, or it may be greater than 10°. , 30° or more.

The head movement control means sets the building layer or its precursor layer laminated on the 2m layer (m is a positive integer) of the nth building layer or its precursor layer as the n+2mth building layer or its precursor layer. , the modeling layer or its precursor layer laminated on the n+1th modeling layer or its precursor layer (m is a positive integer) is the n+1+2mth modeling layer or its precursor layer, and the n+2mth modeling layer or its precursor layer is the n+1+2mth modeling layer or its precursor layer. The locus of movement of the center point of the nozzle row when ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the layer or its precursor layer is defined as a line (line n+2m), and the n+1+2mth built layer or When the locus of movement of the center point of the nozzle row when ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer is a line (line n+1+2m), line n and line n+2m It is preferable that the lines n+1 and n+1+2m overlap, and that the lines n+1 and n+1+2m overlap. In this case, there are essentially only two movement patterns of the head when ejecting ink, and while the movement of the head can be easily controlled, deterioration in printing quality can be suppressed.
Here, the modeling layer or its precursor layer laminated on one layer of the n-th modeling layer or its precursor layer is the n+1-th modeling layer or its precursor layer.

The direction of movement of the head when drawing line n and the direction of movement of the head when drawing line n+1 may be the same direction or opposite directions in the main scanning direction.
Further, the direction of movement of the head when drawing line n and the direction of movement of the head when drawing line n+2m may be the same direction or opposite directions in the main scanning direction. .
Furthermore, the direction of movement of the head when drawing line n+1 and the direction of movement of the head when drawing line n+1+2m may be the same direction or opposite directions in the main scanning direction. .

The head movement control means controls the movement of the head so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 are parallel to each other. After ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the modeling layer or its precursor layer, the head is moved in the main scanning direction to scan above the support without ejecting ink. After that, ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the n+1-th modeling layer or its precursor layer, and after that, the head is moved in the main scanning direction without ejecting ink. It may be moved to pass over the support. In this case, the direction of movement of the head when drawing line n and the direction of movement of the head when drawing line n+1 are the same direction in the main scanning direction. The trajectory of the movement of the head is as shown in FIG. 11, which will be described later.
By doing so, the ink discharge start position in the main scanning direction of the n-th building layer and the ink discharge start position in the main scanning direction of the n+1th building layer will be the same, making it easy to improve the modeling accuracy in the main scanning direction. can be increased.

The head movement control means controls the movement of the head so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 are parallel to each other. After ink is ejected from at least one of the plurality of nozzles in the nozzle row toward the modeling layer or its precursor layer, the head is moved in the sub-scanning direction without ejecting ink, and then the (n+1)th Ink may be ejected from at least one of the plurality of nozzles in the nozzle array toward the modeling layer or its precursor layer, and then the head may be moved in the sub-scanning direction without ejecting ink. In this case, the direction of movement of the head when drawing line n and the direction of movement of the head when drawing line n+1 are opposite directions in the main scanning direction. In this case, the locus of movement of the head is as shown in FIG. 12, which will be described later.
By doing so, the distance that the head moves without ejecting ink is short, so the modeling time can be increased (shortened).

<Ink>
The ink is not particularly limited and can be appropriately selected depending on the purpose, but preferably contains a radiant energy absorber.
Since the ink is usually liquid at room temperature, it preferably contains a liquid component.
The ink may or may not contain a coloring component.
In other words, ink is a modeling liquid.

<<Radiant energy absorber>>
The radiant energy absorber is not particularly limited as long as it absorbs radiant energy, and can be appropriately selected depending on the purpose.
As the radiant energy absorber, a suitably synthesized one may be used, or a commercially available product may be used.
Commercially available products include, for example, CM997A (manufactured by Hewlett-Packard), which is an ink-type formulation containing carbon black. It can also have KHP, bone char, graphite, carbon fibers, chalk or interference pigments. Furthermore, it can include an infrared absorber, a near-infrared absorber, a visible light absorber, a UV light absorber, and the like. For example, examples of inks containing visible light enhancers include dye-based colored inks and pigments, such as the inks known as CM993A and CE042A (both Hewlett-Packard Company) commercially available from Hewlett-Packard Company. Examples include base colored inks.
These may be used alone or in combination of two or more.

The liquid component is not particularly limited and can be appropriately selected depending on the purpose, but water and water-soluble solvents are preferably used, and in particular, water is used as the main component.

The proportion of water in the entire ink is not particularly limited and can be appropriately selected depending on the purpose, but is preferably 40% by mass or more and 85% by mass or less, more preferably 50% by mass or more and 80% by mass or less. When the ratio of water to the total ink is within a preferable range, if the radiant energy absorbing agent applying means is an inkjet head, drying of the nozzle during standby can be suppressed, and the occurrence of liquid clogging and nozzle omission can be reduced. can.

Water-soluble solvents are effective in improving water retention and ejection stability, especially when ink is ejected using an inkjet nozzle. If the water retention ability or ejection stability decreases, the nozzle may become dry and ejection becomes unstable, or liquid clogging may occur, which may reduce the strength and dimensional accuracy of the three-dimensional structure. In this regard, many water-soluble solvents have a higher viscosity and boiling point than water, and these are particularly effective as they can function as wetting agents, anti-drying agents, and viscosity modifiers for ink.

The water-soluble solvent is not particularly limited as long as it is a water-soluble liquid material, and can be changed as appropriate. Examples include alcohols such as ethanol, propanol, and butanol, ethers, and ketones. Specifically, 1,2,6-hexanetriol, 1,2-butanediol, 1,2-hexanediol, 2-pentanediol, 1,3-dimethyl-2-imidazolidinone, 1,3-butane Diol, 1,3-propanediol, 1,4-butanediol, 1,5-pentanediol, 1,6-hexanediol, 2,2-dimethyl-1,3-propanediol, 2,3-butanediol, 2,4-pentanediol, 2,5-hexanediol, 2-ethyl-1,3-hexanediol, 2-pyrrolidone, 2-methyl-1,3-propanediol, 2-methyl-2,4-pentanediol , 3-methyl-1,3-butanediol, 3-methyl-1,3-hexanediol, N-methyl-2-pyrrolidone, N-methylpyrrolidinone, β-butoxy-N,N-dimethylpropionamide, β- Methoxy-N,N-dimethylpropionamide, γ-butyrolactone, ε-caprolactam, ethylene glycol, ethylene glycol-n-butyl ether, ethylene glycol-n-propyl ether, ethylene glycol phenyl ether, ethylene glycol mono-2-ethylhexyl ether, Ethylene glycol monoethyl ether, glycerin, diethylene glycol, diethylene glycol-n-hexyl ether, diethylene glycol methyl ether, diethylene glycol monoethyl ether, diethylene glycol monobutyl ether, diethylene glycol monomethyl ether, diglycerin, dipropylene glycol, dipropylene glycol n-propyl ether, Propylene glycol monomethyl ether, dimethyl sulfoxide, sulfolane, thiodiglycol, tetraethylene glycol, triethylene glycol, triethylene glycol ethyl ether, triethylene glycol dimethyl ether, triethylene glycol monobutyl ether, triethylene glycol methyl ether, tripropylene glycol, Propylene glycol-n-propyl ether, tripropylene glycol methyl ether, trimethylolethane, trimethylolpropane, propylpropylene diglycol, propylene glycol, propylene glycol-n-butyl ether, propylene glycol-t-butyl ether, propylene glycol phenyl ether, propylene Examples include glycol monoethyl ether, hexylene glycol, polyethylene glycol, polypropylene glycol, and the like.

The proportion of the water-soluble solvent to the entire ink is not particularly limited and can be changed as appropriate, but is preferably 5% by mass or more and 60% by mass or less, more preferably 10% by mass or more and 50% by mass or less, It is more preferably 15% by mass or more and 40% by mass or less. When the ratio of the water-soluble solvent to the entire ink is 5% by mass or more, the water retention ability of the ink can be improved, and it is possible to prevent the ink inside the head from drying during standby and causing ejection failure. can. Further, it is possible to prevent the discharge amount from being different during the check performed in advance and during the actual discharge, and it becomes easier to obtain a three-dimensional molded object having the desired strength and shape. When the proportion of the water-soluble solvent to the entire ink is 60% by mass or less, the viscosity of the ink does not become too high and the ejection stability can be improved. Further, since it is possible to suppress the solubility of the powder resin particles from decreasing, it is possible to prevent the strength of the three-dimensional structure from decreasing. Moreover, the drying time of the three-dimensional structure is not too long, and it is possible to suppress a decrease in manufacturing efficiency and deformation of the three-dimensional structure.

Other components of the ink include, for example, wetting agents, anti-drying agents, viscosity modifiers, surfactants, penetrants, crosslinking agents, antifoaming agents, pH adjusters, preservatives, anti-mold agents, colorants, and preservatives. Conventionally known materials such as agents and stabilizers can be added without restriction.

[Ink preparation method]
The method for preparing the ink is not particularly limited and can be selected as appropriate depending on the purpose. For example, a radiant energy absorber and other components may be added to a liquid component such as water or a water-soluble solvent. An example is a method of adding, mixing and stirring.

<Powder layer forming means and powder layer forming process>
The powder layer forming means is not particularly limited as long as it forms a precursor layer, which is a powder layer made of a three-dimensional modeling powder material, on the support, and can be appropriately selected depending on the purpose. For example, a combination of a mechanism for supplying powder material for three-dimensional modeling and a mechanism for forming a powder layer while leveling the supplied powder material for three-dimensional modeling may be used.
The powder layer forming step is not particularly limited as long as it is a step of forming a precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on the support, and can be appropriately selected depending on the purpose. For example, it can be performed by a powder layer forming means.

In an apparatus for producing a three-dimensional object, the ink contains a radiant energy absorber and includes a powder layer forming means for forming a precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on a support; It is preferable to have a radiant energy applying means for applying radiant energy to the applied precursor layer.
The method for producing a three-dimensional object includes a powder layer forming step in which the ink contains a radiant energy absorber and forms a precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on a support; It is preferable to have a radiant energy applying step of applying radiant energy to the applied precursor layer.

In the apparatus for manufacturing a three-dimensional object, it is preferable that the radiant energy applying means applies radiant energy to the precursor layer after the head passes over the precursor.
In the method for manufacturing a three-dimensional object, it is preferable that the radiant energy is applied to the precursor layer in the radiant energy applying step after the head passes over the precursor.

<<Powder material for three-dimensional modeling>>

The powder material for three-dimensional modeling contains, for example, resin particles, and further contains other components as necessary.
The powder material for three-dimensional modeling has a powder or particle form.

-Resin particles-
Resin particles mean particles containing a resin component. Note that, hereinafter, the resin particles may be referred to as "resin powder" or "resin powder." In addition to the resin component, the resin particles may contain other components as necessary.
The resin component is not particularly limited and can be appropriately selected depending on the purpose, but a thermoplastic resin is preferred.

Thermoplastic resin means a resin that plasticizes and melts when heated.
The thermoplastic resin is not particularly limited and can be appropriately selected depending on the purpose, and examples thereof include crystalline resins, amorphous resins, liquid crystal resins, and the like. As the thermoplastic resin, a crystalline resin is preferable. Further, as the thermoplastic resin, a resin having a large difference between the melting start temperature and the recrystallization temperature during cooling is preferable.
Note that the crystalline resin is a resin whose melting point peak is detected in a measurement based on ISO3146 (plastic transition temperature measurement method, JIS K7121).

Examples of the thermoplastic resin include polyolefin, polyamide, polyester, polyether, polyphenylene sulfide, polyacetal (POM: polyoxymethylene), polyimide, and fluororesin. These may be used alone or in combination of two or more.

Examples of the polyolefin include polyethylene (PE) and polypropylene (PP).

Examples of the polyamide include polyamide 410 (PA410), polyamide 6 (PA6), polyamide 66 (PA66), polyamide 610 (PA610), polyamide 612 (PA612), polyamide 11 (PA11), and polyamide 12 (PA12); Semi-aromatic polyamides such as polyamide 4T (PA4T), polyamide MXD6 (PAMXD6), polyamide 6T (PA6T), polyamide 9T (PA9T), and polyamide 10T (PA10T) are mentioned.

Examples of polyester include polyethylene terephthalate (PET), polybutadiene terephthalate (PBT), and polylactic acid (PLA). Among these, those having an aromatic group partially containing terephthalic acid or isophthalic acid are preferred from the viewpoint of imparting heat resistance.

Examples of polyethers include polyarylketones and polyethersulfones.
Examples of the polyarylketone include polyetheretherketone (PEEK, melting point: 340°C), polyetherketone (PEK), polyetherketoneketone (PEKK), polyaryletherketone (PAEK), polyetheretherketoneketone ( PEEKK), polyetherketoneetherketoneketone (PEKEKK), and the like.

The thermoplastic resin may have two melting point peaks, such as PA9T, for example. A thermoplastic resin having two melting point peaks completely melts at a temperature equal to or higher than the melting point peak on the high temperature side.

Furthermore, polyphthalamide, polyphenylene sulfide, liquid crystal polymer, polysulfone, polyetherimide, polyamideimide, polyetheretherketone, polytetrafluoroethylene, and the like are called "super engineering plastics."

Examples of the amorphous resin include polyvinyl chloride, polystyrene, AS resin, ABS resin, methacrylic resin, polycarbonate, polyphenylene ether, polyarylate, polysulfone, polyether sulfone, polyetherimide, polyamideimide, and the like.

The thermoplastic resin is preferably at least one selected from super engineering plastics. When the thermoplastic resin is a super engineering plastic, the tensile strength, heat resistance, chemical resistance, and flame retardance of the three-dimensional object to be formed can be improved, and the three-dimensional object can also be used for industrial purposes. It is advantageous in this respect.

-Other ingredients-
Other ingredients may include fillers and other fillers, which can increase strength, heat resistance, and various resistances, provide new functions, and reduce costs. Become.
The filler is not particularly limited and can be appropriately selected depending on the purpose as long as it does not impair the function of the antibacterial material, and includes, for example, a fluidizing agent, a filler, a leveling agent, and the like.
When the powder material for three-dimensional modeling contains a fluidizing agent, it is preferable because a layer etc. of the powder material for three-dimensional modeling can be easily and efficiently formed, and when it contains a filler, the strength of the obtained three-dimensional model increases significantly, Inclusion of a leveling agent is preferable because it improves the wettability of the powder material for three-dimensional modeling and is advantageous in terms of the process, such as reducing the amount of ink used.
Although inorganic fine particles such as silica and titanium oxide can be used as the fluidizing agent, organic fine particles are more preferable.
As the organic fine particles, known resin materials such as general-purpose resins and engineering plastics can be used, and examples thereof include fine particles of acrylic resin, melamine resin, vinyl resin, amide resin, and the like.
The volume average particle diameter of the organic fine particles is preferably 10 nm or more and 2,000 nm or less, more preferably 10 nm or more and 1,000 nm or less. If the volume average particle size is smaller than this range, agglomeration due to Van der Waals force between particles cannot be ignored, making handling difficult in terms of labor safety such as handling and fine powder suction, and if larger, the desired fluidization effect may not be achieved. This is because a problem arises in that it is not possible to obtain .

--- Method for producing powder material for three-dimensional modeling --
As a method for producing the powder material for three-dimensional modeling, various mixers and kneaders that are known batch-type or continuous-type kneading machines can be used. Specifically, the Henschel Mixer (manufactured by Nippon Coke Industry Co., Ltd.), Super Mixer (manufactured by Kawada Manufacturing Co., Ltd.), Q Mixer (manufactured by Nippon Coke Industry Co., Ltd.), Mechano Fusion System (manufactured by Hosokawa Micron Co., Ltd.), Mechano Mill (manufactured by Okada Seiko Co., Ltd.) (manufactured by Osaka Chemical Co., Ltd.), and when preparing small amounts of powder, equipment such as the Turbuler mixer (manufactured by Shinmaru Enterprises), Oster blender (manufactured by Osaka Chemical Co., Ltd.), and hybridization system (manufactured by Nara Kikai Seisakusho) are also used. can do.

--Physical properties of powder materials for three-dimensional modeling --
The volume average particle size (primary particle size) of the powder material for three-dimensional modeling is preferably 1 μm or more and 100 μm or less, more preferably 10 μm or more and 80 μm or less. If the particles are smaller than this range, the Van der Waals force between the particles cannot be ignored and they tend to aggregate, making handling difficult in terms of handling, fine powder suction, etc., and occupational safety. If the size is larger than this, even if the particles are closely packed together, the voids between the particles will be large, resulting in a serious problem of a decrease in density, strength, or modeling accuracy.
As for the characteristics of the powder material for three-dimensional modeling, when its angle of repose is measured, it is preferably 60 degrees or less, more preferably 50 degrees or less, and even more preferably 40 degrees or less.
When the angle of repose is 60 degrees or less, the powder material for three-dimensional modeling can be efficiently and stably arranged at a desired location on the support.
Note that the angle of repose can be measured using, for example, a powder property measuring device (Powder Tester PT-N type, manufactured by Hosokawa Micron Co., Ltd.).

<<Formation of powder layer>>
There are no particular restrictions on the method for disposing the powder material for three-dimensional modeling on the support, and it can be selected as appropriate depending on the purpose. A method using a known counter rotation mechanism (counter roller) used in the selective laser sintering method described, a method of spreading powder material for three-dimensional modeling into a thin layer using members such as brushes, rollers, blades, etc. Preferred methods include a method of pressing the surface of the modeling powder using a pressing member to spread it into a thin layer, and a method of using a known powder layering device.

The powder material for three-dimensional modeling can be placed in a thin layer on the support using a counter rotation mechanism (counter roller), a brush or a blade, a pressing member, etc., for example, as follows.
That is, on a support disposed within an outer frame (sometimes referred to as a "mold", "hollow cylinder", "cylindrical structure", etc.) so that it can rise and fall while sliding on the inner wall of the outer frame. A powder material for three-dimensional modeling is placed on the material using a counter rotation mechanism (counter roller), a brush, a roller or a blade, a pressing member, etc. At this time, when using a support that can be moved up and down within the outer frame, the support is placed at a position slightly below the upper end opening of the outer frame, that is, downward by the thickness of the powder layer. The powder material for three-dimensional modeling is placed on the support. As described above, the powder material for three-dimensional modeling can be placed in a thin layer on the support.

Further, the powder material for three-dimensional modeling can be placed in a thin layer on the support body automatically and easily using a known powder layering device. A powder layering device generally includes a recoater for layering powder material for three-dimensional modeling, a movable supply tank for supplying the powder material for three-dimensional modeling onto a support, and a thin layer of powder material for three-dimensional modeling. It is equipped with a movable modeling tank for placing and stacking. In powder layering equipment, the surface of the supply tank can always be raised slightly above the surface of the build tank by raising the supply tank, lowering the build tank, or both, and the recoater is removed from the supply tank side. The powder material for three-dimensional modeling can be arranged in a thin layer using the method, and the thin layers of the powder material for three-dimensional modeling can be stacked by repeatedly moving the recoater.

The thickness of the powder layer is not particularly limited and can be appropriately selected depending on the purpose, but for example, the average thickness per layer is preferably 1 μm or more and 500 μm or less, more preferably 10 μm or more and 200 μm or less.
When the thickness is 1 μm or more, the strength of the solidified product (three-dimensional model) of the three-dimensional model powder material (layer) formed by applying ink to the three-dimensional model powder material is sufficient, and the subsequent sintering etc. If the thickness is 500 μm or less, there will be no problems such as deformation during processing or handling. ) dimensional accuracy can be guaranteed.
Note that the average thickness is not particularly limited and can be measured according to a known method.

When the powder layer forming means forms the powder layer, it is preferable to preheat the powder material for three-dimensional modeling so that the temperature of the powder material for three-dimensional modeling becomes a desired temperature. Thereby, it is possible to reduce the irradiation of the radiant energy rays for raising the temperature of the powder material for three-dimensional modeling to the melting point by the solidifying means, and it is also possible to shorten the irradiation time of the radiant energy rays.

The preheating temperature is not particularly limited and can be appropriately selected depending on the purpose, but it is preferably a temperature between the recrystallization temperature and the melting temperature of the resin particles contained in the powder material for three-dimensional modeling. By setting the preheating temperature to a temperature between the recrystallization temperature and the melting temperature of the resin particles, it is possible to maintain the fluidity of the powder when forming the powder layer and prevent the occurrence of warping in the three-dimensional model. Can be suppressed.

The means for preheating the powder material for three-dimensional modeling is not particularly limited and can be selected as appropriate depending on the purpose. For example, heating from above with an infrared heater, heating the modeling tank itself with a contact heater, The following methods are possible.

<Radiant energy application means and radiant energy application process>
The means for applying radiant energy is not particularly limited as long as it applies radiant energy to the precursor layer to which ink has been applied, and can be appropriately selected depending on the purpose.For example, infrared irradiation means, light irradiation means, microwave irradiation means, etc.
The radiant energy applying step is not particularly limited as long as it is a step of applying radiant energy to the precursor layer to which the ink has been applied, and can be appropriately selected depending on the purpose. For example, it is carried out by a radiant energy applying means. be able to.
The radiant energy is not particularly limited and can be appropriately selected depending on the purpose, and includes, for example, infrared rays, electromagnetic waves such as light and radio waves.
The intensity of the radiant energy is not particularly limited and can be appropriately selected depending on the purpose.

<Other processes and other means>
Other processes include, for example, a sintering process.
Other means include, for example, sintering means.

Embodiments of the present invention will be described below with reference to the accompanying drawings. An overview of an example of a device according to a first embodiment of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic plan view of the apparatus, and FIG. 2 is a cross-sectional view of the molded part.

The device for modeling this three-dimensional object (referred to as the three-dimensional modeling device) has a modeling section 1 that laminates powder (powder material for three-dimensional modeling), and a powder layer 31 that is laid out in layers in the modeling section 1. A modeling unit 5 that discharges a modeling liquid 10 (ink) is provided.

The modeling section 1 includes a powder tank 11, a flattening roller 12 as a rotating body that is a flattening member (recoater), and the like. Note that the flattening member may be, for example, a plate-like member (blade) instead of the rotating body.

The powder tank 11 includes a supply tank 21 that supplies the powder 20 and a modeling tank 22 in which the modeling layers 30 are stacked to form a three-dimensional object. Powder is supplied to the supply tank 21 before modeling. The bottom of the supply tank 21 serves as a supply stage 23 and is movable up and down in the vertical direction (Z direction). Similarly, the bottom of the modeling tank 22 serves as a modeling stage 24 that can be raised and lowered in the vertical direction (Z direction). A three-dimensional object is formed by stacking the modeling layers 30 on the modeling stage 24.

The supply stage 23 and the modeling stage 24 are moved up and down in the Z direction by a motor.

The flattening roller 12 supplies the powder 20 supplied onto the supply stage 23 of the supply tank 21 to the modeling tank 22, and flattens it by the flattening roller 12, which is a flattening member, to form a powder layer 31. form.
The flattening roller 12 is arranged so as to be movable back and forth relative to the stage surface in the direction of arrow X along the stage surface (the surface on which the powder 20 is loaded) of the modeling stage 24, and is operated by a reciprocating mechanism. will be moved. Further, the flattening roller 12 is rotationally driven by a motor.

On the other hand, the modeling unit 5 includes a head unit 50 that discharges the modeling liquid 10 onto the powder layer 31 on the modeling stage 24 and a carriage 51 .

The carriage 51 is movably held by a guide member 54.
The carriage 51 is reciprocated in the Y direction, which is the sub-scanning direction, by a Y-direction scanning motor 551, which will be described later, via a sub-scanning movement mechanism composed of a pulley and a belt.

In the head unit 50, a plurality of nozzle rows each having a plurality of nozzles that eject liquid are arranged. The nozzle array of the head unit 50 discharges modeling liquid (ink). The nozzle rows of the head unit 50 can also discharge colored modeling liquids (modeling liquids containing a radiant energy absorber) in colors such as cyan, magenta, yellow, and black. Note that the head configuration is not limited to this.

The modeling unit 5 has a slider section 72 movably held by a guide member 71, and the entire modeling unit 5 can reciprocate in the X direction (main scanning direction). The entire modeling unit 5 is reciprocated in the X direction by a scanning mechanism including a motor, which will be described later.

Here, details of the modeling section 1 will be explained.
The powder tank 11 is box-shaped and includes two tanks (a supply tank 21 and a modeling tank 22) with open tops. A supply stage 23 is disposed inside the supply tank 21, and a modeling stage 24 is disposed inside the modeling tank 22 so as to be movable up and down.

The side surface of the supply stage 23 is arranged so as to be in contact with the inner surface of the supply tank 21. The side surface of the modeling stage 24 is arranged so as to be in contact with the inner surface of the modeling tank 22. The upper surfaces of the supply stage 23 and the modeling stage 24 are kept horizontal.

The flattening roller 12 transfers and supplies the powder 20 from the supply tank 21 to the modeling tank 22, flattens the surface by leveling it, and forms a powder layer 31 which is layered powder with a predetermined thickness. .
This flattening roller 12 is a rod-shaped member that is longer than the inner dimensions of the modeling tank 22 and the supply tank 21 (i.e., the width of the part where powder is provided or charged), and is moved by a reciprocating mechanism to flatten the stage surface. It is moved back and forth in the X direction (main scanning direction) along.
The supply stage 23 is raised by a predetermined distance, the modeling stage 24 is lowered by a predetermined distance, and while the flattening roller 12 is being rotated by the motor, it passes over the supply tank 21 and the modeling tank 22 from outside the supply tank 21. Move horizontally. Thereby, the powder 20 is transferred and supplied onto the modeling tank 22, and the powder layer 31 is formed by flattening the powder 20 while the flattening roller 12 passes over the modeling tank 22.

In this embodiment, the powder tank 11 of the modeling section 1 has two tanks, the supply tank 21 and the modeling tank 22. It is also possible to provide a structure in which the material is supplied and flattened by a flattening means.

Next, an overview of the control section of the three-dimensional modeling apparatus will be described with reference to FIG. 3. FIG. 3 is a block diagram of the three-dimensional modeling apparatus control section.
The control unit 500 includes a CPU 501 that controls the entire three-dimensional modeling apparatus, a ROM 502 that stores programs including programs for causing the CPU 501 to execute control of three-dimensional modeling operations including control related to the present invention, and other fixed data. , and a RAM 503 that temporarily stores modeling data and the like.
The control unit 500 includes a non-volatile memory (NVRAM) 504 for retaining data even when the power of the device is cut off. Further, the control unit 500 includes an ASIC 505 that processes image processing that performs various signal processing on image data, and other input/output signals for controlling the entire apparatus.
The control unit 500 includes an external I/F 506 for transmitting and receiving data and signals used when receiving modeling data from an external modeling data creation device 600. Note that the modeling data creation device 600 is a device that creates modeling data by slicing the final form of the molded object into each modeling layer, and is configured with an information processing device such as a personal computer.
The control unit 500 includes an I/O 507 for receiving detection signals from various sensors.
The control section 500 includes a head drive control section 508 that drives and controls the head unit 50.
The control unit 500 includes a motor drive unit 512 that drives a motor that constitutes a Y-direction scanning mechanism 552 that moves the carriage 51 of the head unit 50 in the Y direction (sub-scanning direction), and a motor drive unit 512 that drives the motor that configures the Y-direction scanning mechanism 552 that moves the carriage 51 of the head unit 50 in the ) is provided with a motor drive section 510 that drives a motor constituting an X-direction scanning mechanism 550 that moves the X-direction scanning mechanism 550 to
The control unit 500 may include a motor drive unit that drives a motor that constitutes a Z-direction lifting mechanism that moves (raises and lowers) the carriage 51 of the head unit 50 in the Z-direction. Note that the entire modeling unit 5 may be moved up and down in the Z direction.
The control unit 500 includes a motor drive unit 513 that drives the motor 27 that moves the supply stage 23 up and down, and a motor drive unit 514 that drives the motor 28 that moves the modeling stage 24 up and down.
The control unit 500 includes a motor drive unit 515 that drives a motor 553 of a reciprocating mechanism that moves the flattening roller 12, and a motor drive unit 516 that drives a motor 26 that rotationally drives the flattening roller 12.
The I/O 507 of the control unit 500 receives a detection signal from a temperature/humidity sensor 560 that detects temperature and humidity as environmental conditions of the device, and detection signals from other sensors.
An operation panel 522 is connected to the control unit 500 for inputting and displaying information necessary for this device.
Note that a modeling device is configured by the modeling data creation device 600 and the three-dimensional modeling device (powder layered modeling device) 601.
Ink ejection is controlled by the control section 500 and executed by the head unit 52, for example, based on the modeling data created by the modeling data creation means.
The head movement control means constitutes a part of the control section 500, for example.
Control of head movement by the head movement control means may be performed according to data of a predetermined head movement pattern recorded in a ROM.
Further, the head movement control unit may control the movement of the head according to data of a pattern of head movement created in real time by the control unit 500. Further, the modeling data creation means creates head movement pattern data together with the printing data, temporarily stores the printing data and movement pattern data in the RAM, and stores the movement pattern data stored in the RAM. It may be carried out according to the following.

Next, the flow of manufacturing (modeling) a three-dimensional object will be described with reference to FIGS. 4A to 4E. FIGS. 4A to 4E are schematic diagrams illustrating the flow of modeling a three-dimensional object.

A description will be given starting from the state in which the first modeling layer 30 is formed on the modeling stage 24 of the modeling tank 22.
When forming the next modeling layer 30 on this modeling layer 30, as shown in FIG. 4A, the supply stage 23 of the supply tank 21 is raised in the Z1 direction, and the modeling stage 24 of the modeling tank 22 is lowered in the Z2 direction. let
At this time, the descending distance of the modeling stage 24 is set so that the distance between the upper surface (powder layer surface) of the modeling tank 22 and the lower part (lower tangent part) of the flattening roller 12 is Δt. This interval Δt corresponds to the thickness of the powder layer 31 to be formed next. The interval Δt is preferably about several tens to 100 μm.

Next, as shown in FIG. 4B, the powder 20 located above the upper surface level of the supply tank 21 is moved in the X2 direction (toward the modeling tank 22 side) while rotating the flattening roller 12 in the forward direction (arrow direction). By moving, the powder 20 is transferred and supplied to the modeling tank 22 (powder supply).

Furthermore, as shown in FIG. 4C, the flattening roller 12 is moved parallel to the stage surface of the modeling stage 24 of the modeling tank 22, and as shown in FIG. A powder layer 31 having a temperature of Δt is formed (flattening). After forming the powder layer 31, the flattening roller 12 is moved in the X1 direction and returned to the initial position, as shown in FIG. 4D.
Here, the flattening roller 12 can be moved while maintaining a constant distance from the upper surface level of the modeling tank 22 and the supply tank 21. By being able to keep the movement constant, the powder 20 is conveyed onto the modeling tank 22 by the flattening roller 12, and the powder with a uniform thickness Δt is placed on the modeling tank 22 or on the already formed modeling layer 30. Layer 31 can be formed.

Thereafter, as shown in FIG. 4E, droplets of the modeling liquid 10 are ejected from the head unit 50. At this time, the points at which the droplets of the modeling liquid 10 are ejected are points based on the modeling data obtained by slicing the final form of the modeled object into each modeling layer by the modeling data creation device 600.

Next, a new modeling layer 30 is formed by repeating the process of forming the powder layer 31 by supplying and flattening the powder described above and the process of discharging the modeling liquid by the head unit 50. At this time, the new modeling layer 30 and the underlying modeling layer 30 are integrated to constitute a part of the three-dimensional shaped object.
Thereafter, the step of forming the powder layer 31 by supplying and flattening the powder and the step of discharging the modeling liquid by the head unit 50 are repeated as many times as necessary to complete the three-dimensional shaped object.

Note that the modeling liquid can contain a binder component. Alternatively, it is also possible to coat the powder with a binder component that aggregates (solidifies) by applying a modeling liquid to the powder.
The modeling liquid can also include a radiant energy absorber. A radiant energy source can be provided on either the left or right side of the head unit 50 or both. Alternatively, the radiant energy source can be located at a fixed location independent of the head.

The state of modeling by the head unit will be explained using FIG. 5.
As shown in FIG. 5, droplets of the modeling liquid are dropped from the nozzle 55 while the head unit 50 scans the powder (three-dimensional modeling powder material) surface of the modeling tank 22 in the X direction (main scanning direction). Powder is recoated thereon, and droplets of the modeling liquid are dropped from the nozzle 55 while the head unit 50 scans in the X direction, and this is repeated to create the model.

Problems caused by ejection failure will be explained using FIG. 6.
As shown in FIG. 6, if there is a defective ejection nozzle 56 in the head unit 50, a line of ejection failure occurs in the X direction. If modeling is continued in this state, the fixing force will be insufficient at the line position, resulting in insufficient strength.

An example of trying to eliminate quality defects due to ejection defects will be described with reference to FIGS. 7A and 7B.
As shown in FIG. 7A, while the head unit 50 scans in the X direction at the position A, droplets of the modeling liquid are dropped from the nozzle 55 toward the precursor of the n-th modeling layer. Powder is recoated thereon to form a precursor for the n+1th modeling layer. Shift the head unit 50 to position B (Y direction: sub-scanning direction). Next, while scanning in the X direction at position B, the head unit 50 drops droplets of the modeling liquid from the nozzle 55 toward the precursor of the n+1th modeling layer. At this time, the pattern printed by the head unit 50 is a pattern shifted in the opposite direction by the same distance as the distance by which the head unit 50 is shifted in the Y direction. As a result, streaks of non-ejection are no longer continuous in the Z-axis direction (thickness direction of the shaped layer), and strength may be ensured.
The locus of the center point of the nozzle row at this time will be explained using FIG. 7B. A line represents the locus of the center point _Cn of the nozzle row when the head unit 50 is scanning in the X direction at position A and dropping droplets of the modeling liquid from the nozzles toward the precursor of the n-th modeling layer. If expressed as , it becomes line _Ln . On the other hand, the trajectory of the center point C n+ _{1 of} the nozzle row when the head unit 50 drops droplets of the modeling liquid from the nozzles toward the precursor of the n+1th modeling layer while scanning in the X direction at the position B. When expressed by a line, it becomes line L _n+1 . Here, although the line L _n and the line L _n+1 do not overlap, they are parallel to each other.
In the case of this conventional technology, if there are multiple defective nozzles ejecting, and furthermore, there are non-ejecting nozzles at the same interval as the shift distance in the Y direction (Fig. 8), the result is a continuous line of ejecting defects in the Z-axis direction. This results in insufficient strength. Although this problem occurs infrequently, it is a very serious problem and can greatly reduce the reliability of the product.

An embodiment of the present invention will be described using FIGS. 9A and 9B.
As shown in FIG. 9A, the head unit 50 scans the powder (three-dimensional modeling powder material) surface of the modeling tank 22 from the position A in the X direction (upward in the drawing) and in the Y direction (leftward direction). ), droplets of the modeling liquid are dropped from the nozzle 55 toward the precursor of the n-th modeling layer. Powder is recoated thereon to form a precursor for the n+1th modeling layer. Furthermore, while the head unit 50 scans in the X direction (upward in the drawing) and moves in the Y direction (rightward) from position B, droplets of the modeling liquid are sent from the nozzle 55 as a precursor to the n+1th modeling layer. Drip towards the body. At this time, the pattern to be printed by the head unit 50 from the position B is a pattern shifted in the opposite direction by the same distance as the distance the head unit 50 has moved from the position A in the Y direction. Then, repeat this process to create the model.
As a result, there is no continuous portion in the Z-axis direction other than the points where the non-ejection lines intersect, and strength can be ensured.
The locus of the center point of the nozzle row at this time will be explained using FIG. 9B. From position A, the head unit 50 scans in the X direction (upward in the drawing) and moves in the Y direction (leftward), applying droplets of the modeling liquid from the nozzle to the precursor of the n-th modeling layer. If the locus of the center point C _n of the nozzle row when the liquid is dropped toward the direction is expressed by a line, it becomes line L _n . On the other hand, from position B, the head unit 50 scans in the X direction (upward in the drawing) and moves in the Y direction (rightward), spraying droplets of the modeling liquid from the nozzle as a precursor of the n+1th modeling layer. When the locus of the center point C _n+1 of the nozzle array when dripping toward the body is expressed by a line, it becomes line L _n+1 . Here, the line L _n and the line L _n+1 do not overlap and are not parallel.

Furthermore, with reference to FIG. 10, a case will be described in which there are a plurality of ejection failure nozzles, and furthermore, there are ejection failure nozzles at the same interval as the shift distance in the Y direction. FIG. 10 shows a case where there are two defective ejection nozzles and they are present at the same interval as the shift distance of the head unit 50. In this case, if the modeling method explained using FIGS. 9A and 9B is used, the four points where the respective lines intersect are continuous in the Z direction, but there is no continuous part in the Z axis direction other than those four points. It turns out. Thereby, even if there are a plurality of defective ejection nozzles, the decrease in strength can be minimized.

In this embodiment, a method (BJ method or HSS method) in which a printing liquid is ejected from an inkjet head onto a molding area on a thin layered powder surface is shown as an example, but it can also be applied to an MJ method or the like. In other words, instead of recoating the powder, the object is manipulated in the Z direction.

FIG. 11 is a schematic explanatory diagram illustrating an example of the operating direction of the head unit.
While moving the head unit 50 in the direction C, the modeling liquid is discharged. Return the head unit 50 in the direction D (X direction). Recoat the powder. The modeling liquid is discharged while moving the head unit 50 in the E direction. Return the head unit 50 in the F direction (X direction). Recoat the powder.
Three-dimensional modeling can be achieved by operating the head unit 50 so as to draw a so-called horizontal figure eight.

FIG. 12 is a schematic explanatory diagram illustrating an example of the operating direction of the head unit.
While moving the head unit 50 in the direction C, the modeling liquid is discharged. Return the head unit 50 in the direction D (Y direction). Recoat the powder. The modeling liquid is discharged while moving the head unit 50 in the E direction. Return the head unit 50 in the F direction (Y direction). Recoat the powder.
Three-dimensional modeling can be achieved by operating the head unit 50 so as to draw a so-called figure eight horizontally and vertically.

In one embodiment, the pattern to be printed by the head unit 50 during scanning in the C or E direction in FIGS. 11 and 12 is created in advance by the modeling data creation device 600 in FIG. 3 so as to be shifted in the Y direction. 3D modeling can be achieved by applying the pattern.

In one embodiment, the pattern printed by the head unit 50 during scanning in the C or E direction in FIGS. 11 and 12 is created so as to be shifted in the Y direction in real time by the head drive control unit 508 in FIG. By applying the created patterns, three-dimensional modeling can be realized.

Aspects of the present invention are, for example, as follows.
<1> A three-dimensional object manufacturing device that manufactures a three-dimensional object by laminating modeling layers formed using ink,
a head having a nozzle row in which a plurality of nozzles for ejecting the ink are arranged side by side in the sub-scanning direction;
main scanning moving means for moving the head in a main scanning direction that is a direction perpendicular to the nozzle row;
sub-scanning moving means for moving the head in the sub-scanning direction;
a support that supports the modeling layer;
When the head is moved above the support and the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the modeling layer or its precursor layer, the n-th modeling layer or a line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer; The nozzle array when the ink is ejected from at least one of the plurality of nozzles of the nozzle array toward the n+1-th modeling layer or its precursor layer laminated on the modeling layer or its precursor layer. head movement control means for controlling the movement of the head so that when the locus of movement of the center point of the head is represented by a line (line n+1), the line n and the line n+1 do not overlap and are not parallel; ,
An apparatus for manufacturing a three-dimensional object, characterized by having the following.
<2> The head movement control means controls the head so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 are parallel to each other. The manufacturing apparatus for the three-dimensional modeling apparatus described in <1> above controls the movement of the three-dimensional modeling apparatus.
<3> The three-dimensional molding according to any one of <1> to <2>, wherein the head movement control means repeatedly controls the movement of the head, and the three-dimensional molded object is manufactured by laminating the three-dimensional molding layers. It is a device for manufacturing things.
<4> The ink contains a radiant energy absorber,
Powder layer forming means for forming the precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on the support;
radiant energy applying means for applying radiant energy to the precursor layer to which the ink is applied;
The apparatus for producing a three-dimensional structure according to any one of <1> to <3> above.
<5> The three-dimensional modeling according to <4>, wherein the application of radiant energy to the precursor layer by the radiant energy application means is performed after the head passes above the precursor. It is a device for manufacturing things.
<6> A method for manufacturing a three-dimensional object, which manufactures a three-dimensional object by laminating modeling layers formed using ink,
a head having a nozzle row in which a plurality of nozzles for ejecting the ink are arranged side by side in the sub-scanning direction;
main scanning moving means for moving the head in a main scanning direction that is a direction perpendicular to the nozzle row;
sub-scanning moving means for moving the head in the sub-scanning direction;
a support that supports the modeling layer;
using
When the head is moved above the support and the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the modeling layer or its precursor layer, the n-th modeling layer or a line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer; The nozzle array when the ink is ejected from at least one of the plurality of nozzles of the nozzle array toward the n+1-th modeling layer or its precursor layer laminated on the modeling layer or its precursor layer. Controlling the movement of the head so that when the locus of movement of the center point of is represented by a line (line n+1), the line n and the line n+1 do not overlap and are not parallel;
A method for manufacturing a three-dimensional object, characterized by comprising:
<7> Controlling the movement of the head so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 are parallel to each other. 6> is a method for manufacturing a three-dimensional modeling apparatus.
<8> The method for manufacturing a three-dimensional object according to any one of <6> to <7>, wherein the three-dimensional object is manufactured by repeatedly controlling the movement of the head and stacking the three-dimensional object. .
<9> The ink contains a radiant energy absorber,
a powder layer forming step of forming the precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on the support;
a step of applying radiant energy to the precursor layer to which the ink is applied;
The method for producing a three-dimensional structure according to any one of <6> to <8> above.
<10> The method for producing a three-dimensional structure according to <9>, wherein the application of radiant energy to the precursor layer in the radiant energy application step is performed after the head passes above the precursor. .

According to the apparatus for manufacturing a three-dimensional object according to any one of <1> to <5> and the method for manufacturing a three-dimensional object according to <6> to <10>, the various problems in the conventional art are solved, The above object of the present invention can be achieved.

1 Modeling section 5 Modeling unit 10 Modeling liquid 11 Powder tank 12 Flattening roller 20 Powder 21 Supply tank 22 Modeling tank 23 Supply stage 24 Modeling stage 26 Motor 27 Motor 28 Motor 30 Modeling layer 31 Powder layer 50 Head unit 51 Carriage 52 Head unit 54 Guide member 55 Nozzle 56 Defective ejection nozzle 71 Guide member 72 Slider section 500 Control section 500A Main control section 504 Non-volatile memory (NVRAM)
508 Head drive control section 510 Motor drive section 512 Motor drive section 513 Motor drive section 514 Motor drive section 515 Motor drive section 522 Operation panel 550 X direction scanning mechanism 551 Y direction scanning motor 552 Y direction scanning mechanism 553 Motor 560 Temperature/humidity sensor 600 Printing data creation device

Japanese Patent Application Publication No. 2017-105141

Claims (10)

A three-dimensional object manufacturing device that manufactures a three-dimensional object by laminating modeling layers formed using ink,
a head having a nozzle row in which a plurality of nozzles for ejecting the ink are arranged side by side in the sub-scanning direction;
main scanning moving means for moving the head in a main scanning direction that is a direction perpendicular to the nozzle row;
sub-scanning moving means that is driven simultaneously with the main-scanning moving means and moves the head in the sub-scanning direction;
a support that supports the modeling layer;
When the head is moved above the support and the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the modeling layer or its precursor layer, the n-th modeling layer or a line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer; The nozzle array when the ink is ejected from at least one of the plurality of nozzles of the nozzle array toward the n+1-th modeling layer or its precursor layer laminated on the modeling layer or its precursor layer. head movement control means for controlling the movement of the head so that when the locus of movement of the center point of the head is represented by a line (line n+1), the line n and the line n+1 do not overlap and are not parallel; ,
An apparatus for manufacturing a three-dimensional object, characterized by having the following. The head movement control means controls the movement of the head so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 become parallel. The three-dimensional structure manufacturing apparatus according to claim 1, wherein the three-dimensional object manufacturing apparatus is controlled. 3. The three-dimensional molded object manufacturing apparatus according to claim 1, wherein the three-dimensional molded object is manufactured by repeatedly controlling the movement of the head by the head movement control means so that the three-dimensional molded object is laminated. the ink contains a radiant energy absorber;
Powder layer forming means for forming the precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on the support;
radiant energy applying means for applying radiant energy to the precursor layer to which the ink is applied;
An apparatus for manufacturing a three-dimensional structure according to any one of claims 1 to 3. 5. The three-dimensional structure manufacturing apparatus according to claim 4, wherein the radiant energy applying means applies the radiant energy to the precursor layer after the head passes above the precursor. . A method for manufacturing a three-dimensional object, the method comprising manufacturing a three-dimensional object by laminating modeling layers formed using ink,
a head having a nozzle row in which a plurality of nozzles for ejecting the ink are arranged side by side in the sub-scanning direction;
main scanning moving means for moving the head in a main scanning direction that is a direction perpendicular to the nozzle row;
sub-scanning moving means that is driven simultaneously with the main-scanning moving means and moves the head in the sub-scanning direction;
a support that supports the modeling layer;
using
When the head is moved above the support and the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the modeling layer or its precursor layer, the n-th modeling layer or a line (line n) represents the locus of the center point of the nozzle row when the ink is ejected from at least one of the plurality of nozzles of the nozzle row toward the precursor layer; The nozzle array when the ink is ejected from at least one of the plurality of nozzles of the nozzle array toward the n+1-th modeling layer or its precursor layer laminated on the modeling layer or its precursor layer. Controlling the movement of the head so that when the locus of movement of the center point of is represented by a line (line n+1), the line n and the line n+1 do not overlap and are not parallel;
A method for producing a three-dimensional object, comprising: 7. Movement of the head is controlled so that when the line n is reversed by 180 degrees with the main scanning direction as an axis, the reversed line n and the line n+1 are parallel to each other. A method for manufacturing a three-dimensional object . The method for manufacturing a three-dimensional object according to any one of claims 6 to 7, wherein the three-dimensional object is manufactured by repeatedly controlling the movement of the head and stacking the three-dimensional object. the ink contains a radiant energy absorber;
a powder layer forming step of forming the precursor layer, which is a powder layer made of a powder material for three-dimensional modeling, on the support;
a step of applying radiant energy to the precursor layer to which the ink is applied;
The method for manufacturing a three-dimensional structure according to any one of claims 6 to 8. The method for manufacturing a three-dimensional structure according to claim 9, wherein the application of radiant energy to the precursor layer in the radiant energy application step is performed after the head passes above the precursor.