JP2007021705A - Three-dimensional molding method and device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To surely prepare a three-dimensional molded object by preventing dissociation of a part formed by an auxiliary material at the time of cutting and a part formed by a molding material. <P>SOLUTION: The contour of a three-dimensional shape of the three-dimensional molded object to be prepared is projected on two-dimensional plane. The contour projected on the two-dimensional plane is offset by prescribed quantity in a prescribed direction. At least one of the cutting for the three-dimensional shape corresponding to a contour position before the offset at the inside of the offset contour and the cutting for the three-dimensional shape corresponding to the contour position before the offset at the outside of the offset contour is performed in a state in which a region formed by either one of the auxiliary material and the molding material is supported by a region formed by other materials different from the materials forming the former region. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a three-dimensional modeling method and a three-dimensional modeling apparatus, and more specifically, three-dimensional spatial expansion while laminating an auxiliary material layer formed of an auxiliary material and a modeling material layer formed of a modeling material. The present invention relates to a three-dimensional modeling method and a three-dimensional modeling apparatus that produce a three-dimensional modeled object.

  Conventionally, after a predetermined portion of the auxiliary material layer formed of the auxiliary material is removed by cutting with a cutting tool such as an end mill, a modeling material layer is formed on the removed portion with a modeling material, and these are removed. A three-dimensional modeling apparatus is known in which a desired three-dimensional modeled object can be obtained by repeatedly performing a two-dimensional cross-sectional shape by laminating (for example, Patent Document 1).

  In the 3D modeling apparatus as described above, since the second layer is laminated on the already formed first layer (see FIG. 1A), the second auxiliary layer is the first layer. They are fixed with mutual adhesive strength to the modeling material layer (see FIG. 1B). Then, the auxiliary material layer of the second layer is cut and formed by an end mill as a cutting tool (see FIG. 1C).

However, depending on the shape and size of the three-dimensional structure to be produced, the type of modeling material and auxiliary material, etc., the mutual adhesive force is lost to the cutting resistance by the cutting tool, and the auxiliary material layer laminated on the modeling material layer The first modeling material layer and the second auxiliary material layer are dissociated in the process of cutting and molding (see the broken line shown in FIG. 1 (d)), and as a result, a three-dimensional structure is formed. There was a fear that they could not.
JP-A-8-318573

  The present invention has been made in view of the various problems of the conventional techniques as described above, and the object of the present invention is to be formed by a part formed by an auxiliary material and a modeling material at the time of cutting. It is intended to provide a three-dimensional modeling method and a three-dimensional modeling apparatus capable of preventing a dissociated portion from being separated and reliably producing a three-dimensional modeled object.

  In order to achieve the above object, the invention according to claim 1 of the present invention includes a step of cutting an auxiliary material layer formed of an auxiliary material and a step of cutting a modeling material layer formed of a modeling material. After repeatedly performing the three-dimensional modeling method of removing the auxiliary material layer and preparing the three-dimensional modeled object composed of the modeling material layer, the contour of the three-dimensional shape of the three-dimensional modeled object to be manufactured is set on a two-dimensional plane. Projecting and offsetting the contour projected on the two-dimensional plane by a predetermined amount in a predetermined direction, cutting for a three-dimensional shape inside the offset contour, and a tertiary on the outside of the offset contour At least one of the cutting for the original shape is performed by changing the region formed by one of the auxiliary material and the modeling material to the other material different from the material forming the region. Is obtained to carry out while being supported by the area formed me.

  Moreover, the invention according to claim 2 of the present invention is a first method for extracting a contour in an XYZ orthogonal coordinate system of the three-dimensional shape from three-dimensional model data indicating the three-dimensional shape of the three-dimensional structure to be produced. A second stage in which the contour extracted in the first stage is projected onto an XY plane in an XYZ Cartesian coordinate system; and the contour projected in the second stage is projected in a predetermined direction on the XY plane. For the production of the three-dimensional structure, it is divided into a third stage for obtaining an offset contour by offsetting a predetermined amount and an inner side and an outer side of the offset contour obtained in the third stage. According to the fourth stage of generating machining path data indicating the tool path of the tool and the machining path data generated in the fourth stage, the contour position before the offset is inside or outside of the offset contour. Corresponding to the deviation, the state formed by supporting the region formed by one of the auxiliary material and the modeling material by the region formed by the other material different from the material forming the region. And a fifth step of repeatedly performing the step of cutting the region formed by the auxiliary material and the step of cutting the region formed by the modeling material.

  Moreover, invention of Claim 3 among this invention produces a three-dimensional structure by repeatedly performing the process of cutting the area | region formed with the auxiliary material, and the process of cutting the area | region formed with modeling material. In the three-dimensional modeling apparatus, auxiliary material application means for discharging the auxiliary material in the form of droplets from a discharge port located at a predetermined interval from a region to which the auxiliary material is applied, and a region to which the modeling material is to be applied The modeling material application means for discharging the modeling material in the form of droplets from a discharge port located with a gap between, the auxiliary material discharged from the auxiliary material application means, and the modeling material discharged from the modeling material application means A processing table for producing a three-dimensional structure by the material, a cutting means for cutting an area formed by the auxiliary material or an area formed by the modeling material, Auxiliary material application means, the modeling material application means and the cutting means are driven such that the cutting means moves relative to the processing table in a three-dimensional direction, and the three-dimensional shape of the three-dimensional structure to be produced. The above-mentioned 3D modeling is performed by projecting the contour of the contour onto the two-dimensional plane, offsetting the contour projected onto the two-dimensional plane by a predetermined amount in a predetermined direction, and dividing the offset contour into the inside and the outside. Generating the processing path data indicating the movement path of the auxiliary material applying means, the modeling material applying means and the cutting means for manufacturing the object, and driving the driving means according to the generated processing path data; At least one of cutting for a three-dimensional shape inside the offset contour and cutting for a three-dimensional shape outside the offset contour is: And a control means for controlling the region formed by one of the auxiliary material and the modeling material to be performed in a state where the region is supported by the other material different from the material forming the region. It is a thing.

  Moreover, invention of Claim 4 among this invention is the photocurable resin which the said modeling material hardens | cures with the irradiated light in the invention of Claim 3, and was discharged from the said modeling material application means. It has light irradiation means for irradiating the modeling material with light to cure the photo-curing resin.

  The present invention has an excellent effect that a part formed by an auxiliary material and a part formed by a modeling material can be prevented from dissociating at the time of cutting, and a three-dimensional structure can be reliably manufactured.

  Hereinafter, an example of an embodiment of a 3D modeling method and a 3D modeling apparatus according to the present invention will be described in detail with reference to the accompanying drawings.

  FIG. 2 shows a schematic configuration explanatory diagram of an example of an embodiment of a three-dimensional modeling apparatus that realizes a three-dimensional modeling method according to the present invention. The three-dimensional modeling apparatus 10 shown in FIG. 2 is formed in a U-shape formed by a pair of substantially quadrangular columnar support portions 12L and 12R extending in the vertical direction and a bottom portion 12B connecting the support portions 12L and 12R. The gate-type arm portion 12 is provided. Furthermore, the rail part 14 supported by the upper ends of each of the pair of support parts 12L and 12R, and the rail part 14 are within a predetermined range in the X-axis direction in the XYZ orthogonal coordinate system (see the reference diagram showing the coordinate system in FIG. 2). The carriage 16 is disposed so as to be freely movable.

  Further, a spindle 28, a dispenser 24 for discharging an auxiliary material, and a modeling material are discharged to a head (see FIGS. 2 and 3) provided movably within a predetermined range in the Z-axis direction with respect to the carriage 16. A dispenser 26 is also provided.

  Further, on the frame portion 18, a table 22 having a flat upper surface that is movable within a predetermined range in the Y-axis direction is disposed. On the upper surface 22a, an auxiliary material layer formed by an auxiliary material and a modeling process are provided. A modeling material layer formed of the material is laminated to form a three-dimensional modeled object.

  Note that the three-dimensional modeling apparatus 10 is configured such that the dispenser 24, the dispenser 26, and the spindle 28 are moved along the Z axis in accordance with the movement of the head based on the processing path data output from the microcomputer 200 (see FIG. 4). In the direction, as the carriage 16 moves, the X axis direction is moved, and the table 22 is moved in the Y axis direction.

  Accordingly, the relative positional relationship between the end mill 30 supported by the dispenser 24, the dispenser 26 and the spindle 28 and the three-dimensional structure formed on the table upper surface 22a moves in any direction in the X, Y, and Z axis directions. It is possible.

  Next, FIG. 3 shows a schematic configuration explanatory view (perspective view) in which the carriage 16 portion of the three-dimensional modeling apparatus 10 shown in FIG. 2 is enlarged, and detailed description will be given below.

  The dispenser 24 is designed so that auxiliary material accommodated in a tank (not shown) is supplied to the syringe 24b with a built-in heater, and can heat the auxiliary material stored in the syringe to a predetermined temperature.

  In this embodiment, a metal, particularly a low melting point alloy is used as an auxiliary material. For example, solder.

  The low melting point alloy heated to a predetermined temperature is melted in the syringe 24b, connected to the syringe 24b and discharged from the discharge port 24a located at the tip of the dispenser 24, and drops into a predetermined droplet. It is controlled so that a predetermined amount is applied to the position.

  The dispenser 26 is designed so that the modeling material accommodated in a tank (not shown) is supplied to the syringe 26b. One drop of the modeling material is connected to the syringe 26b from the discharge port 26a located at the tip of the dispenser 26. It is controlled so that a single droplet is ejected and applied to a predetermined position as a flying droplet.

  In this embodiment, an ultraviolet curable resin that cures when irradiated with ultraviolet rays is used as the modeling material.

  Further, a light guide member 42 is disposed so as to be positioned on the outer peripheral side of the discharge port 26a of the dispenser 26. The light guide member 42 is designed such that the optical fiber 50 for irradiating the ultraviolet rays drawn from the introduction tube portion 42c is positioned on the inclined surface 42s through the connecting portion 42b. For this reason, the ultraviolet rays irradiated from the front end portion of the optical fiber 50 are irradiated in a 360 ° ring shape, and are condensed in a spot shape directly below the through-hole 42h drilled in a substantially central portion of the main body portion 42a (see FIG. 8 (a)).

  Therefore, as described above, the ultraviolet curable resin applied at a predetermined position from the discharge port 26a of the dispenser 26 is controlled so as to be cured by the ultraviolet rays irradiated from the light guide member 42.

  The end mill 30 is connected to a rotating spindle 28 and cuts an auxiliary material layer and a modeling material layer by a cutting portion 30a.

  Here, as shown in FIG. 4, the microcomputer 200 that controls the overall operation of the three-dimensional modeling apparatus 10 performs a process according to a program stored in a read-only memory (ROM) (not shown). A processing device (CPU) 202, an area as a working area when processing path generation processing described later is performed under the control of the CPU 202, an area for storing processing path data generated by the processing path generation processing, and the like are set. A memory 204 including a random access memory (RAM); an input unit 206 for inputting three-dimensional model data indicating a three-dimensional shape of the three-dimensional structure from the outside of the three-dimensional structure apparatus 10 under the control of the CPU 202; Based on the three-dimensional model data input by the input unit 206 under control, a machining path is generated. A calculation unit 208 that performs processing, and an output unit 210 that outputs processing path data generated by the processing path generation processing performed by the calculation unit 208 under the control of the CPU 202 to the drive system of the three-dimensional modeling apparatus 10. It is configured.

  The drive system of the three-dimensional modeling apparatus 10 to which the processing path data is output from the output unit 210 is configured by a motor or the like, and the end mill 30, the dispenser 24, the dispenser 26, and the table 22 are set in a predetermined manner based on the processing path data. Move in the direction.

  In the above configuration, first, the machining path data generation process executed by the three-dimensional modeling apparatus 10 described above will be described with reference to the flowchart of the machining path generation process routine shown in FIG. The manufacturing process of the three-dimensional structure in the three-dimensional structure forming apparatus 10 will be specifically described by taking the three-dimensional structure 100 shown in e) as an example.

  In the description of the processing path data generation process (see FIG. 5), the three-dimensional structure 300 shown in FIG. 6A-1 is used as the target three-dimensional structure for generating the processing path data. To do. This three-dimensional structure 300 has a three-dimensional shape in which the cross-sectional shape along the Z-axis direction in the XYZ orthogonal coordinate system is substantially trapezoidal as shown in FIG.

  When the flowchart of the machining path generation processing routine shown in FIG. 5 is started for the three-dimensional structure 300 (see FIGS. 6A-1 and 6A-2), for example, first, in step S502. Based on the control of the CPU 202, a process of reading 3D model data indicating the 3D shape of the 3D structure 300 is performed via the input unit 206. The read 3D model data is stored in the memory 204 under the control of the CPU 202.

  In this embodiment, the 3D model data expressed by polygons is used as the 3D model data read by the processing in step S502. In other words, a three-dimensional three-dimensional shape having a three-dimensional spatial extent indicated by the three-dimensional model data is represented by a combination of polygons called polygons, and the surface of the three-dimensional shape is divided into polygons and numerical data It has become.

  Subsequent to the process of step S502, in step S504, a process of extracting an outline from the three-dimensional shape indicated by the three-dimensional model data read by the process of step S502 is performed.

  Here, since the 3D model data represented by the polygon is read in the previous step S502, the contour extracted from such 3D model data has a plurality of polygons corresponding to the polygonal polygon representing the 3D shape. And a plurality of line segments connecting the vertices. FIG. 6B schematically shows an outline 400 extracted from the three-dimensional model data of the three-dimensional structure 300 shown in FIGS. 6A-1 and 6A-2. The contour 400 is a contour corresponding to many small triangular polygons constituting the surface of the three-dimensional structure 300 of the three-dimensional structure 300, and each vertex of the contour represents an XYZ coordinate value in the XYZ orthogonal coordinate system. It is what you have.

  When the process of step S504 is completed, the process proceeds to the process of step S506, and the process of projecting the contour extracted by the process of step S504 on the two-dimensional plane is performed (see the broken line shown in FIG. 6C-1). In this projection process, a three-dimensional contour 400 (see FIG. 6B) having a plurality of vertices each having XYZ coordinate values is projected onto an XY plane which is a two-dimensional plane. The Z coordinate value of each vertex of the contour 500 (see FIG. 6C-2) projected on the XY plane is “Z coordinate value = 0”.

  Subsequent to the process of step S506, in step S508, the process of offsetting the contour of the three-dimensional shape projected on the two-dimensional plane by the process of step S506 is performed (see the broken line shown in FIG. 6D).

  The offset process in step S508 will be described in more detail with reference to FIGS. 7A to 7E. First, the three-dimensional shape projected on the XY plane, which is a two-dimensional plane, by the process in step S506. The contour 500 includes eight vertices P1, P2, P3, P4, P5, P6, P7, P8 and a plurality of line segments connecting the plurality of vertices P1, P2, P3, P4, P5, P6, P7, P8. L1, L2, L3, L4, L5, L6, L7, L8, L9, L10, L11, L12, L13, L14, L15, L16, L17, and L18 (see FIG. 7A).

  Of these plurality of vertices P1 to P8 and the plurality of line segments L1 to L18, an offset process is performed on a vertex and a line segment located at the outermost contour of the contour 500 as processing targets. That is, in the case of the contour 500, the vertices P1, P2, P3, and P4 and the line segments L1, L2, L3, and L4 are subjected to offset processing (see FIG. 7B).

  Based on the XY coordinate values of the vertices P1, P2, P3, and P4 to be processed, the inclinations of the line segments L1, L2, L3, and L4 to be processed with respect to the X-axis direction are calculated, and the direction according to the inclination is calculated. Offset. At this time, the offset amount is set to a predetermined amount in advance. In this embodiment, at least the radius of the cutting portion 30a of the end mill 30, that is, the total length along the direction orthogonal to the axial direction of the cutting tool. It is set so as to secure 1/2 or more.

  Specifically, a vertical line whose inclination with respect to the X-axis direction is 90 ° is offset to the left side in the XY plane so that the X coordinate value of the vertex of the line segment is reduced by a predetermined offset amount. Further, the horizontal line whose inclination with respect to the X-axis direction is 0 ° is offset downward in the XY plane so that the Y coordinate value of the vertex of the line segment is reduced by a predetermined offset amount. In addition, a diagonal line having an inclination with respect to the X-axis direction greater than 0 ° and less than 90 ° is offset to the left side in the XY plane so that the X coordinate value of the vertex of the line segment is reduced by a predetermined offset amount. .

  According to the offset direction and the offset amount described above, as shown in FIG. 7C, among the four line segments L1, L2, L3, and L4 to be processed of the contour 500, the line segment L1 and the line segment L3 are X Since the vertical line has an inclination of 90 ° with respect to the axial direction, the X coordinate values of the vertices P1 and P2 of the line segment L1 and the vertices P3 and P4 of the line segment L3 are reduced by a predetermined offset amount, and the left side in the XY plane To the line segment LA1 and line segment LA3 after offset (refer to the black arrows shown in FIG. 7C).

  Also, since the line segment L2 and the line segment L4 are horizontal lines having an inclination of 0 ° with respect to the X-axis direction, the Y coordinate values of the vertices P2 and P3 of the line segment L2 and the vertices P4 and P1 of the line segment L4 are a predetermined offset amount. In such a manner, it is offset downward in the XY plane so as to become the line segment LA2 and the line segment LA4 after the offset (see the white arrow shown in FIG. 7C).

  Further, a straight line passing through the two vertices of the line segments LA1, LA2, LA3, LA4 after the offset is calculated, and an intersection of the calculated straight lines is calculated. At this time, the straight line calculated from the adjacent line segments in the original contour 500 is targeted as the intersection.

  As a result, in the contour 500, as shown in FIG. 7 (d), two straight lines passing through the vertices of the offset line segments LA1 and LA2 with respect to the adjacent line segment L1 and line segment L2 in the contour 500 The intersection PA2 between them is calculated. Further, for the line segment L2 and the line segment L3 adjacent to each other in the contour 500, an intersection PA3 of two straight lines passing through the respective vertices of the offset line segments LA2 and LA3 is calculated. In addition, for the line segment L3 and the line segment L4 that are adjacent to each other in the contour 500, an intersection PA4 of two straight lines that pass through the vertices of the offset line segments LA3 and LA4 is calculated. Further, for the line segment L4 and the line segment L1 adjacent to each other in the contour 500, an intersection PA1 between two straight lines passing through the respective vertices of the offset line segments LA4 and LA1 is calculated.

  A polygonal contour 500A (see FIG. 7E) formed by connecting the four intersections PA1, PA2, PA3, PA4 calculated in this way is projected onto the two-dimensional plane by the offset processing in step S508. It is an offset contour generated from the original contour 500 (see FIG. 6C-2 and FIG. 7A).

  If an offset contour (see the contour 500A shown in FIG. 7E) is acquired by the processing in step S508, the process proceeds to step S510, and machining path data is generated inside the offset contour (FIG. 6E). )reference). The processing path data generated by the process of step S510 is for creating the three-dimensional structure 300 (see FIGS. 6A-1 and 6A-2) indicated by the three-dimensional model data in the three-dimensional structure forming apparatus 10. The tool (tool), specifically, the movement path (tool path) of the end mill 30 and the dispensers 24 and 26 is shown.

  At this time, since processing path data is generated inside the offset contour in the process of step S510, processing path data capable of manufacturing the entire three-dimensional structure indicated by the three-dimensional model data is not generated. In the process of step S510, the contour 500 having a three-dimensional shape projected on the two-dimensional plane by the process of step S506 developed on the XY plane (see FIG. 6C-2), and step S508. The offset contour 500A (see FIG. 7 (e)) generated by the above processing is compared, and the three-dimensional shape of the three-dimensional structure corresponding to the portion of the contour 500 before offset located in the offset contour 500A is obtained. Processing path data that can be partially created is generated.

  Subsequently to step S510, in step S512, machining path data is generated outside the offset contour (see FIG. 6F). By the processing in step S512, processing path data capable of producing the remaining part of the three-dimensional structure that has not been processed by the processing in step S510 is generated.

  That is, the entire three-dimensional structure indicated by the three-dimensional model data is created by the processing path data generated by the process of step S510 and the processing path data generated by the process of step S512. Specifically, in the case of the three-dimensional structure 300 (see FIGS. 6A-1 and 6A-2), based on the processing path data generated by the process of step S510, FIG. A part of the three-dimensional structure 300 shown in FIG. 6 can be produced, and the remaining part of the three-dimensional structure 300 shown in FIG. 6 (g-2) is based on the processing path data generated by the processing in step S512. It can be produced.

  When the process of step S512 is completed, the process proceeds to the process of step S514, and the processing path data generated by the processes of step S510 and step S512 is output to the drive system of the 3D modeling apparatus 10 by the output unit 210 based on the control of the CPU 202. To do.

  Then, when the process of step S514 is completed, this machining path generation process routine is terminated.

  As described above, when machining path data is generated by the machining path generation process (see FIG. 5) of the calculation unit 208 and is output to the drive system of the three-dimensional modeling apparatus 10, the end mill 30 and the dispenser are based on the machining path data. 24, the dispenser 26, and the table 22 each move in a predetermined direction, and the production of the three-dimensional structure indicated by the three-dimensional model data proceeds.

  Here, the process of producing the three-dimensional structure 100 shown in FIG. 9E will be specifically described. Note that in FIGS. 8 to 9, the portion formed of the auxiliary material is appropriately shown with light ink.

  First, droplets of UV curable resin, which is a modeling material, are supplied in a substantially dot shape from a discharge port 26a of a dispenser 26 located at a predetermined interval from the upper surface 22a of the table 22 to a predetermined position on the table upper surface 22a. Thus, a three-dimensional shape in which the amount of cutting by the end mill 30 is minimized is formed (see FIGS. 8A and 8B).

  At this time, as described above, the light guide portion 42 irradiates ultraviolet rays, and the ultraviolet curable resin is simultaneously cured.

  The modeling material layer 102 thus formed by the ultraviolet curable resin as the modeling material is cut by the end mill 30, and the modeling material layer 102 ′ after being cut has an outer surface 102 ′ a having a desired shape ( (Refer FIG.8 (c)).

  Next, flying droplets of a low-melting-point alloy as an auxiliary material are placed on the modeling material layer 102 ′ on the modeling material layer 102 ′ from the discharge port 24a of the dispenser 24 positioned at a predetermined distance from the upper surface 102′b of the modeling material layer 102 ′. Is supplied in a substantially dot shape (see FIG. 8D), and a three-dimensional shape is formed in which the amount of cutting by the end mill 30 is minimized, solidified by natural cooling, and the auxiliary material layer 104 is formed. (See FIGS. 8 (e-1) and (e-2)).

  The auxiliary material layer 104 (see FIGS. 8 (e-1) and (e-2)) formed of the low melting point alloy as the auxiliary material in this way has a three-dimensional shape in which the cutting amount by the end mill 30 can be minimized, This corresponds to the entire auxiliary material layer 104 ′ (see FIGS. 9B-1 and 9B-2) necessary for producing the three-dimensional structure 100 indicated by the three-dimensional model data. In FIGS. 8E-1 and 8E-2, a portion corresponding to the auxiliary material layer 104 'in the auxiliary material layer 104 is indicated by a broken line.

  That is, as shown in FIGS. 10 (a-1), (a-2), (b-1), and (b-2), if the entire auxiliary material layer 104 is cut by the end mill 30, the auxiliary material having a desired shape is obtained. The material layer 104 ′ can be obtained.

  However, since the production of the three-dimensional structure 100 proceeds according to the processing path data generated by the processing path generation processing (see FIG. 5) in the three-dimensional modeling apparatus 10, FIGS. 10 (b-1) and 10 (b-2) As shown in FIG. 5, the entire auxiliary material layer 104 is not cut and formed at a time.

  Only a part of the auxiliary material layer 104 is cut by the end mill 30 in accordance with the machining path data generated inside the contour offset by the process of step S510, thereby obtaining an outer surface 104′a having a desired shape (FIG. 8 ( f-1) (see f-2)). The cutting of the auxiliary material layer 104 at this stage is a cutting for a three-dimensional shape corresponding to the contour position before offset inside the offset contour, and the obtained outer surface 104′a is a three-dimensional structure. A part of the outer surface of the auxiliary material layer 104 ′ necessary for manufacturing 100, that is, an outer surface located within the offset contour of the auxiliary material layer 104 ′.

  Subsequently, the dispenser 26 moves in accordance with the machining path data generated inside the contour offset by the process of step S510, and the dispenser is dispensed at the location where the outer surface 104′a has been cut out earlier, that is, within the offset contour. The droplets of UV curable resin, which is a modeling material, are supplied in approximately dots from the 26 discharge ports 26a, and the UV light is irradiated by the light guide portion 42 to cure the UV curable resin, and the modeling material layer 106a is laminated ( FIG. 9 (a-1) (a-2) reference).

  Here, since the modeling material is supplied from the dispenser 26 in the offset contour in accordance with the processing path data, the modeling material layer 106a obtained by supplying the modeling material at this stage is a modeling material layer necessary for producing the three-dimensional modeled object. 106 ′ (see FIGS. 9 (d-1) and 9 (d-2)), more specifically, the amount of cutting by the end mill 30 to form a portion located within the offset contour of the modeling material layer 106 ′. It has a three-dimensional shape that can be minimized.

  The modeling material layer 106 a has an inner surface bonded to the outer surface 104 ′ a of the auxiliary material layer 104 and a modeling material made of an ultraviolet curable resin that is the same material located in the lower layer of the modeling material layer 106. The auxiliary material layer 104 laminated on the modeling material layer 102 ′ is stably attached to the modeling material layer upper surface 102′b by the modeling material layer 106 because it is connected to the layer 102 ′ and has a predetermined mutual adhesive force. It is integrated with the modeling material layer 102 ′ in a fixed state.

  If the modeling material layer 106a is thus laminated on the auxiliary material layer 104 as shown in FIGS. 9A-1 and 9A-2, next, it is generated outside the contour offset by the process of step S512. According to the processed processing path data, the process shifts to the processing outside the offset contour, and the portion located outside the offset contour of the auxiliary material layer 104, that is, the portion not covered by the modeling material layer 106a of the auxiliary material layer 104 is the end mill. The auxiliary material layer 104 ′ after being cut by 30 has an outer surface 104′b having a desired shape (see FIGS. 9B-1 and 9B-2).

  At this time, as described above, the auxiliary material layer 104 is stably fixed to the modeling material layer upper surface 102′b, that is, the auxiliary material layer 104 can be accurately cut, and the outer surface 104′a, An auxiliary material layer 104 ′ made of 104′b is obtained. That is, the cutting of the auxiliary material layer 104 was offset with the cutting for the three-dimensional shape corresponding to the contour position before the offset inside the offset contour (see FIGS. 8 (f-1) and (f-2)). It is divided into cutting for a three-dimensional shape corresponding to the contour position before offset outside the contour (see FIGS. 9B-1 and 9B-2), and the region made of the auxiliary material is a modeling material It cuts in the state supported by the area | region which consists of.

  Subsequently, the dispenser 26 moves in accordance with the machining path data generated outside the contour offset by the process of step S512, and the dispenser is located at a location where the outer surface 104′b has been cut out earlier, that is, outside the offset contour. 26, droplets of UV curable resin, which is a modeling material, are supplied in a substantially dot shape, and UV light is irradiated by the light guide portion 42 to cure the UV curable resin, and the modeling material layer 106b is laminated ( (Refer FIG.9 (c-1) (c-2)).

  Here, since the fabrication of the three-dimensional structure 100 proceeds according to the processing path data generated by the processing path generation process (see FIG. 5), the modeling material layer 106 ′ (FIG. 9) necessary for the fabrication of the three-dimensional structure 100 is performed. (D-1) (see d-2)), the material supply for the three-dimensional shape corresponding to the contour position before the offset inside the offset contour (FIG. 9 (a-1) (a- 2)) and the supply of the material for the three-dimensional shape corresponding to the pre-offset contour position outside the offset contour (see FIGS. 9 (c-1) and 9 (c-2)). The modeling material layer 106a and the modeling material layer 106b are each formed in a three-dimensional shape in which the cutting amount by the end mill 30 for obtaining the modeling material layer 106 ′ is minimized.

  The modeling material layers 106a and 106b thus formed by the ultraviolet curable resin as the modeling material are cut and formed by the end mill 30, and the modeling material layer 106 ′ after the cutting molding has an outer surface 106′a having a desired shape. (See FIGS. 9D-1 and 9D-2).

  Then, the three-dimensional structure 100 ′ composed of the modeling material layers 102 ′ and 106 ′ and the auxiliary material layer 104 ′ shown in FIGS. 9 (d-1) and (d-2) is removed from the upper surface 22 a of the table 22. Then, it is heated to a predetermined temperature. Then, the low melting point alloy which is an auxiliary material for forming the auxiliary material layer 104 ′ is thermally dissolved and removed, and a three-dimensional structure 100 (see FIG. 9E) constituted by the modeling material layers 102 ′ and 106 ′ is obtained. .

  As described above, in the three-dimensional modeling apparatus 10 according to the present invention, when cutting the auxiliary material layer 104 stacked on the modeling material layer 102 ′, the processing path data generated by the processing path generation process (see FIG. 5). Then, the three-dimensional shape at the contour position before the offset is three-dimensionally cut and formed at the location within the offset contour (see FIGS. 8 (f-1) and (f-2)), and before the offset at the location outside the offset contour. The three-dimensional shape at the contour position is three-dimensionally cut and formed (see FIGS. 9B-1 and 9B-2), and the auxiliary material layer 104 made of the auxiliary material is supported by the modeling material (modeling material layer 106a). Therefore, the auxiliary material layer 104 can be cut without losing the cutting resistance by the end mill 30, and the three-dimensional structure can be reliably manufactured, and an accurate three-dimensional structure is manufactured. It is possible.

  In particular, since the modeling material layer 106a is in contact with the surface of the auxiliary material layer 104 and is connected to the modeling material layer 102 ′ (see FIGS. 9A-1 and 9A-2), the modeling material layer 106a and the modeling material layer 106a are formed. The auxiliary material layer 104 can be supported on the lower modeling material layer 102 ′ formed of different materials by the strong mutual adhesive force caused by the connection between the same materials generated with the material layer 102 ′. It is possible to produce a high-quality three-dimensional structure by maintaining the mutual adhesive force superior to the cutting resistance and realizing accurate cutting.

  Therefore, even if it is a case where the mutual adhesive force is poor depending on the shape and size of the three-dimensional structure to be manufactured, or the type and combination of the modeling material and auxiliary material, the tertiary according to the present invention. According to the original modeling method, it is possible to prevent the part formed by the auxiliary material and the part formed by the modeling material from being dissociated in the middle of the production of the three-dimensional modeled object by losing the cutting resistance of the cutting by the cutting tool. Can do. In other words, the present invention has high versatility, and according to the present invention, the range of materials that can be used is greatly expanded, and a variety of three-dimensional structures can be produced.

  Furthermore, in the above-described three-dimensional modeling apparatus 10, the processing path generation process (see FIG. 5) automatically uses a three-dimensional model data indicating the three-dimensional modeled object to be produced, with a simple process, Since the machining path data is generated separately for the inside and the outside of the offset contour, cutting is performed while supporting the model material or support material with poor mutual adhesion force with the other material by the offset area according to the machining path data. can do.

  Therefore, according to the present invention, the model material and the support material having poor mutual adhesive strength are alternately deposited and cut, and finally the support material is melted and cut from one direction with the tool only by the model material. Then, when forming a three-dimensional shape in which the inside that cannot be shaped is hollow, the material can be supported by a simpler and faster method, which is effective for three-dimensional modeling.

  The embodiment described above may be modified as described in the following (1) to (9).

  (1) In the above-described embodiment, the 3D model data expressed by polygons is read from the outside in step S502 of the processing path data generation process (see FIG. 5). However, the present invention is not limited to this. Of course, the 3D model data used in the process of generating the machining path data may be stored in advance in the 3D modeling apparatus or created in the 3D modeling apparatus. May be.

  Furthermore, various data can be used as the three-dimensional model data, and is not limited to the three-dimensional model data expressed by polygons. For example, the three-dimensional model data includes a plurality of mesh points having XYZ coordinate values in the XYZ coordinate system. What is represented by a 3D mesh, what is generated on a solid basis such as 3D shape data in a CAD (Computer Aided Design) system, or is generated from 2D shape data indicating a 2D shape For example, various types of data can be used.

  In other words, it may be any three-dimensional shape data that can be processed after step S504 of the processing path data generation process, and may be configured to perform a format conversion process or the like as appropriate according to the data format or the like. Further, according to the 3D model data to be used, the content of the process of extracting the contour from the 3D shape indicated by the 3D model data (see step S504 in FIG. 5) may be appropriately changed.

  (2) In step S508 of the machining path data generation process (see FIG. 5) of the above-described embodiment, the radius of the cutting part 30a of the end mill 30 is used as an offset amount with respect to the X-axis direction of the line segment to be processed. Although the offset is made in the direction corresponding to the inclination (see FIG. 7), the present invention is not limited to this. Of course, the offset is offset when the contour of the three-dimensional shape projected on the two-dimensional plane is offset. The direction and the amount of offset can be changed as appropriate, and the process until obtaining the offset contour is not limited to the above-described embodiment.

  For example, without setting the offset amount to a predetermined value in advance, in the processing path data generation process (see FIG. 5), the offset amount is calculated from the shape of the three-dimensional structure in the previous stage of the offset process. You may comprise.

  Further, in the above-described embodiment, an oblique line whose inclination with respect to the X-axis direction is greater than 0 ° and less than 90 ° is such that the X coordinate value of the vertex of the line segment is reduced by a predetermined offset amount. Offset is made to the left side in the plane (see FIG. 11A). For this reason, even if the shape of the contour of the three-dimensional shape projected on the two-dimensional plane is an elongated shape as shown in FIG. 11B, an offset contour that sufficiently overlaps the contour can be obtained, and the actual cubic The material can be accurately supported in the production process of the original model.

  However, in the case of an oblique line close to the horizontal, that is, an oblique line whose inclination with respect to the X-axis direction is close to 0 °, the X coordinate value of the vertex of the line segment is reduced by a predetermined offset amount, and leftward in the XY plane If the offset occurs, the fixed width may decrease as shown in FIG. Therefore, when the inclination with respect to the X-axis direction of the line segment is greater than 0 ° and equal to or less than a predetermined angle (<90 °), the diagonal line is treated in the same manner as the horizontal line, and the Y coordinate value of the vertex of the line segment is The offset may be reduced downward in the XY plane so as to be reduced by a predetermined offset amount (see FIG. 11D).

  (3) In step S510 and step S512 of the machining path data generation process (see FIG. 5) of the above-described embodiment, machining path data is generated inside and outside with reference to the offset contour. Various conventionally known methods can be used to generate the path data, and machining path data that realizes various tool paths such as contour lines and spirals according to the shape of the 3D model and the type of tool. May be generated within a predetermined range.

  (4) In the above-described embodiment, the auxiliary material layer 104 that is an area formed of the auxiliary material is supported by the modeling material layer 106a that is an area formed of the modeling material. Needless to say, the region formed by the modeling material may be supported by the region formed by the auxiliary material according to the shape of the three-dimensional structure to be manufactured.

  Further, when producing a single three-dimensional structure, both the step of supporting the region formed of the modeling material with the auxiliary material and the step of supporting the region formed of the auxiliary material with the modeling material are performed. Alternatively, only one of the steps may be performed.

  Further, the entire area formed by the modeling material (or auxiliary material) is covered so that it is supported by the area formed by the auxiliary material (or modeling material), or the modeling material supplied in the form of dots ( Alternatively, the region formed by the auxiliary material (or modeling material) may be supported in a series of chains by the auxiliary material). Further, depending on the shape of the three-dimensional structure to be produced, the modeling material (or auxiliary material) is supported so as to support the region formed by the modeling material (or auxiliary material) formed first on the upper surface 22a of the table 22. Material) may be applied.

  For example, in the manufacturing process of the above-described three-dimensional structure 100 (see FIG. 9E), the state shown in FIGS. 8E-1 and 8E-2 is changed to FIGS. 8F-1 and 8F-2. 12, that is, when only a part of the auxiliary material layer 104 is cut by the end mill 30 to obtain the outer surface 104′a, the auxiliary material layer 104 is previously formed as shown in FIG. The modeling material may be applied in a series of chains so as to follow the contour of the outer peripheral edge in contact with the lower modeling material layer 102 ′. Thus, the data for supplying the material along the contour can be easily generated from the shape data of the three-dimensional structure by the arithmetic unit 208, and more reliable cutting can be realized by a very simple process. it can.

  (5) In the above-described embodiment, the low melting point alloy is used as the auxiliary material and the ultraviolet curable resin is used as the modeling material. However, the present invention is not limited to this, and various materials are supported. It may be used as a material or as a modeling material.

  For example, as an auxiliary material, a thermoplastic resin such as wax may be used, and as a modeling material, a photo-curing resin that is cured by visible light, electron beam, or other light of radiation different from ultraviolet rays, Similarly to the auxiliary material, a thermoplastic resin such as wax may be used.

  According to the three-dimensional modeling method according to the present invention, the degree of freedom of the material is widened. For example, a combination of a wax having a low mutual adhesive force and a low melting point alloy can be used.

  (6) In the above-described embodiment, the auxiliary material layer 104 is cut immediately after the modeling material layer 106a is laminated (see FIGS. 9B-1 and 9B-2). Of course, it is not limited to this.

  Depending on the position and shape of the region for supporting the region formed by other materials, or the shape and size of the three-dimensional structure to be produced, and the cutting and laminating processes, for example, the modeling material layer The auxiliary material is applied to support the material, and then the auxiliary material layer and the modeling material layer are laminated on the modeling material layer, and then the modeling material layer supported by the applied auxiliary material is cut. Also good. The three-dimensional modeling method according to the present invention can be changed as appropriate in a three-dimensional model manufacturing process that combines application, lamination, and cutting of materials.

  (7) In the above-described embodiment, the auxiliary material and the modeling material are both supplied in a substantially dot shape. However, the present invention is not limited to this, and only the auxiliary material or Even if only the modeling material is supplied in a substantially dot shape, the material can be applied with high accuracy. Also, depending on the type of auxiliary material and modeling material, the range to be applied, etc., a method different from a substantially dot shape, for example, a linear shape or a predetermined amount may be applied.

  (8) In the above-described embodiment, the 3D modeling apparatus 10 shown in FIGS. 2 and 3 is used. However, the present invention is not limited to this, and various types of 3D modeling apparatus 10 are used. You may make it add a structure or use another modeling apparatus. Further, the processing path data generation process (see FIG. 5) may be performed by an independent computer system separate from the 3D modeling apparatus, and the generated processing path data may be input to the 3D modeling apparatus. Good.

  Further, as the end mill 30 which is a cutting tool, a ball end mill, a flat end mill, a conical end mill, or other cutting tools such as a cutter can be used.

  Various configurations can be employed in which the relative positional relationship between the three-dimensional structure to be produced and the dispensers 24 and 26 is changed in the three-dimensional direction. Moreover, the process of removing the part formed with the auxiliary material to obtain a three-dimensional structure may be performed in a system in the modeling apparatus.

  (9) The above-described embodiment and the modifications shown in (1) to (8) above may be combined as appropriate.

  The present invention can be used in a three-dimensional processing apparatus such as a modeling machine, a two-dimensional engraving apparatus that performs cutting with a tool, or the like when producing parts or design models in trial production or mass production.

FIGS. 1A, 1B, and 1C are explanatory views sequentially showing methods in a conventional three-dimensional modeling apparatus, and FIG. 1D is a perspective explanatory view of FIG. FIG. 2 is a schematic configuration explanatory diagram showing an example of an embodiment of a three-dimensional modeling apparatus that realizes a three-dimensional modeling method according to the present invention. FIG. 3 is a schematic configuration explanatory view (perspective view) showing an enlarged view of a carriage portion of the three-dimensional modeling apparatus shown in FIG. FIG. 4 is a block configuration diagram showing a processing system for realizing the three-dimensional modeling method in the three-dimensional modeling apparatus shown in FIG. FIG. 5 is a flowchart showing a processing path generation process realized by the microcomputer of the three-dimensional modeling apparatus shown in FIG. 6 (a-1) (a-2) (b) (c-1) (c-2) (d) (e) (f) (g-1) (g-2) is shown in FIG. -1) It is explanatory drawing which shows typically the outline | summary of each process in the process path | pass production | generation process shown in FIG. 5 by making the three-dimensional structure shown in (a-2) into production object, FIG.6 (a-2) is FIG. It is sectional drawing in the II-II line | wire of Fig.6 (a-1). FIGS. 7A, 7 </ b> B, 7 </ b> C, 7 </ b> D, and 7 </ b> E are explanatory diagrams schematically showing an outline of offset processing in the machining path generation processing shown in FIG. 5. 8 (a), (b), (c), (d), (e-1), (e-2), (f-1), and (f-2) are the same as those shown in FIG. 8 (e-2) and (f-2) are shown in FIG. 8 (e-1) and (f-1), respectively. It is explanatory drawing which looked at the state from the Z-axis direction. 9 (a-1) (a-2) (b-1) (b-2) (c-1) (c-2) (d-1) (d-2) (e) are according to the present invention. It is explanatory drawing which shows typically the process of producing the three-dimensional structure shown in FIG.9 (e) by a three-dimensional modeling method sequentially, and (a-2) (b-2) (c-2) ( (d-2) is explanatory drawing which looked at the state shown to Fig.9 (a-1) (b-1) (c-1) (d-1) from the Z-axis direction, respectively. FIGS. 10 (a-1), (a-2), (b-1), and (b-2) are a part of the process for producing the three-dimensional structure shown in FIG. 9 (e) by a method different from the present invention. It is explanatory drawing which shows this typically. FIGS. 11A and 11B are explanatory views schematically showing an outline of the offset process in the machining path generation process shown in FIG. 5, and FIGS. 11B and 11C show the machining path generation shown in FIG. 5. It is explanatory drawing which shows typically the other example of the offset process in a process. 12 (a-1), (a-2), (b-1), and (b-2) are explanatory views showing another example of the three-dimensional modeling method according to the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 3D modeling apparatus 12 Gate type arm part 14 Rail part 16 Carriage 18 Frame part 22 Table 24 Dispenser 26 Dispenser 28 Spindle 30 End mill 42 Light guide member 50 Optical fiber 100,300 Three-dimensional structure 400,500 Contour 500A Offset contour

Claims (4)

After repeatedly performing the process of cutting the auxiliary material layer formed of the auxiliary material and the process of cutting the modeling material layer formed of the modeling material, the auxiliary material layer is removed to form a three-dimensional structure composed of the modeling material layer In the three-dimensional modeling method for producing a modeled object,
The three-dimensional shape contour of the three-dimensional structure to be produced is projected onto a two-dimensional plane, the contour projected on the two-dimensional plane is offset by a predetermined amount in a predetermined direction, and the inside of the offset contour At least one of the cutting for the three-dimensional shape in the above and the cutting for the three-dimensional shape outside the offset contour is an area formed by any one of the auxiliary material and the modeling material. A three-dimensional modeling method characterized in that the three-dimensional modeling method is performed in a state of being supported by a region formed of the other material different from the material forming the region. A first stage of extracting a contour in an XYZ orthogonal coordinate system of the three-dimensional shape from the three-dimensional model data indicating the three-dimensional shape of the three-dimensional structure to be produced;
A second step of projecting the contour extracted in the first step onto an XY plane in an XYZ orthogonal coordinate system;
A third step of obtaining an offset contour by offsetting the contour projected in the second step by a predetermined amount in a predetermined direction on the XY plane;
A fourth step of generating machining path data indicating a tool path of a tool for producing the three-dimensional structure, divided into an inside and an outside of the offset contour obtained in the third step;
According to the machining path data generated in the fourth stage, either the auxiliary material or the modeling material corresponding to whether the contour position before offset is inside or outside the offset contour The region formed by the step is caused to be supported by the region formed by the other material different from the material forming the region, and the region formed by the auxiliary material is cut and formed by the modeling material And a fifth step of repeatedly performing the step of cutting the formed region. In the three-dimensional modeling apparatus that repeatedly performs the step of cutting the region formed by the auxiliary material and the step of cutting the region formed by the modeling material to produce a three-dimensional structure,
Auxiliary material application means for discharging the auxiliary material in the form of droplets from a discharge port located at a predetermined interval from a region where the auxiliary material is to be applied,
A modeling material application means for discharging the modeling material in a droplet form from a discharge port located at a predetermined interval from a region where the modeling material is to be applied,
A processing table for producing a three-dimensional structure by the auxiliary material discharged from the auxiliary material application unit and the modeling material discharged from the modeling material application unit,
Cutting means for cutting an area formed by the auxiliary material or an area formed by the modeling material;
Driving means for driving the auxiliary material application means, the modeling material application means and the cutting means to move in a three-dimensional direction relative to the processing table;
The three-dimensional shape contour of the three-dimensional structure to be produced is projected onto a two-dimensional plane, the contour projected on the two-dimensional plane is offset by a predetermined amount in a predetermined direction, and the inside of the offset contour The processing path data generated by generating the processing path data indicating the movement path of the auxiliary material application unit, the modeling material application unit, and the cutting unit for producing the three-dimensional structure is generated separately from the outside. The driving means is driven according to the above, and at least one of cutting for a three-dimensional shape inside the offset contour and cutting for a three-dimensional shape outside the offset contour is the auxiliary material. And a region formed by one of the modeling materials is performed in a state where the region is supported by the other material different from the material forming the region. 3D modeling apparatus characterized by a control means for controlling. In the three-dimensional modeling apparatus according to claim 3,
The modeling material is a photo-curing resin that is cured by irradiated light,
A three-dimensional modeling apparatus comprising light irradiation means for irradiating light to the modeling material discharged from the modeling material application means to cure the photo-curing resin.