JP5272519B2 - 3D modeling apparatus and 3D modeling method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To shape a three-dimensional object having a smooth surface by being combined with powder. <P>SOLUTION: The three-dimensional object is shaped by reciprocating an ejection head on a powder layer and laminating a cross section member formed by solidifying the powder layer by discharging the droplets of a curing liquid. During the movement of the ejection head, all the droplets, instead of being discharged at a time, are discharged intermittently. When the droplet is discharged next, it is discharged at a position between the droplets discharged previously. In this way, the droplet discharged afterward can not spread in the transverse direction by being hindered by a part impregnated with the droplets discharged previously and penetrates preferentially in the depth direction. Since, while the spreading in the transverse direction of the droplet discharged first is suppressed by making the size of the droplet small, the droplet discharged next can penetrate preferentially in the depth direction, the occurrence of unevenness by the spreading of the droplets in the transverse direction can be suppressed in the surface part. <P>COPYRIGHT: (C)2009,JPO&amp;INPIT

Description

The present invention relates to a technique for modeling a three-dimensional object, and more specifically, a powder material (
The present invention relates to a technique for modeling a three-dimensional object by combining powder.

A technique for forming a three-dimensional object while hardening powder with a hardening liquid is known. In this technique, a three-dimensional object is formed by repeating the following operations. First, the powder is thinly spread with a uniform thickness to form a powder layer, and the powder is bonded by discharging droplets of the curable liquid to a desired portion of the powder layer. As a result, only the portion of the powder layer where the droplets of the curable liquid are discharged is bonded to form a thin plate-like member. In the present specification, this thin plate-like member is referred to as a “cross-sectional member”. Next, a thin powder layer is further formed on the powder layer, and droplets of the curable liquid are discharged to a desired portion. As a result, a new cross-sectional member is also formed in the portion of the newly formed powder layer where the curable liquid is discharged. By repeating such operations and laminating thin plate-like cross-sectional members one by one, a three-dimensional object can be formed.

If such 3D modeling technology has only 3D shape data of the object to be modeled,
It is possible to form immediately after combining the powder, and it is not necessary to create a mold prior to shaping, so it is possible to form a three-dimensional object quickly and inexpensively. In addition, since thin plate-like cross-sectional members are layered one by one and shaped, for example, even a complex object having an internal structure can be formed as an integrated shaped object without being divided into a plurality of parts. (For example, patent document 1).

JP 2002-307562 A

However, the three-dimensional object modeled in this way has a problem that it is difficult to model the surface smoothly. That is, when a droplet of the curable liquid is ejected onto the powder layer, the droplet soaks in the depth direction and simultaneously in the lateral direction. And since the penetration of the curable liquid does not become uniform, irregularities are formed on the surface portion of the object. Alternatively, the hardening liquid that has soaked between the powders has hardened in a convex shape, and furthermore, the powder that is not completely bonded to other powders has fallen off, resulting in a dent after that. It can happen. In addition, there is a problem that the properties of the shaped article change due to variations in the bonding speed between powders (curing speed of the curable liquid). That is, when the curing speed is fast, the powders can be firmly bonded together,
Although it is difficult to be deformed even if it receives some external force, on the other hand, if it receives a large external force, it tends to break. On the other hand, when the curing speed is slowed, it is difficult to break even when a large external force is applied, but it may be easily deformed when a relatively small external force is applied.

SUMMARY An advantage of some aspects of the invention is to solve at least a part of the problems described above, and the invention can be implemented as the following forms or application examples.

[Application Example 1] A three-dimensional modeling apparatus according to this application example is a three-dimensional modeling apparatus that models a three-dimensional object by bonding powders together with a curing liquid, and the powder is formed to have a substantially uniform thickness. A powder layer forming means for forming a powder layer by spreading over and a discharge nozzle for discharging droplets of the curable liquid are provided, and curing for discharging the liquid droplets of the curable liquid toward the powder layer is provided. In accordance with the cross section data, a liquid ejection head, cross section data generating means for generating cross section data obtained in each layer when the three dimensional object is cut into layers in a plurality of cross sections, based on the shape data of the three dimensional object, and A cross-section member stacking unit that forms a cross-section member in which the powder of the powder layer is bonded to each other by discharging droplets of the curable liquid from the curable liquid discharge head toward the powder layer; In the cross-sectional member lamination means, Characterized by comprising a penetration speed control means for controlling the seeping speed with respect to the powder layer of the issued the curable liquid.

According to this configuration, prior to the modeling of the three-dimensional object, the cross-sectional data at each layer when the three-dimensional object to be modeled is cut into layers in a plurality of cross sections is based on the shape data of the three-dimensional object. Generate. Then, the powder is spread to a substantially uniform thickness to form a powder layer, and droplets of the curable liquid are discharged from the curable liquid discharge head on the powder layer according to the cross-sectional data. When the curable liquid is supplied, the powders are bonded to each other. Therefore, by discharging droplets of the curable liquid onto the powder layer, the cross section has a thickness corresponding to the thickness of the powder layer and has a three-dimensional object. A member having a cross-sectional shape at (
Cross-sectional member) can be formed. Therefore, a new powder layer is formed on the powder layer on which the cross-section member is formed, and a droplet of the curable liquid is ejected to the powder layer according to the cross-section data. And is laminated on the previously formed cross-sectional member. By repeating such an operation, a three-dimensional object can be formed. Here, when the cross-sectional member is formed, the speed at which the curable liquid discharged from the curable liquid discharge head permeates into the powder layer is controlled. Therefore, by controlling the permeation speed, it is possible to suppress the occurrence of unevenness on the surface portion of the three-dimensional object.

[Application Example 2] The three-dimensional modeling apparatus according to the application example described above discharges a powder layer forming unit that forms a powder layer by spreading the powder to a substantially uniform thickness, and a droplet of the curable liquid. And a curable liquid discharge head for discharging droplets of the curable liquid toward the powder layer while reciprocating on the powder layer, and the three-dimensional object in layers in a plurality of sections. The cross-sectional data generating means for generating the cross-sectional data obtained in each layer when cut into two, based on the shape data of the three-dimensional object, and the liquid of the curable liquid according to the cross-sectional data while reciprocating the curable liquid discharge head By discharging the droplets toward the powder layer, a cross-sectional member in which the powders of the powder layer are combined is formed, and the cross-sectional member is stacked on the cross-sectional member formed in the lower layer Cross-sectional member laminating means, The member stacking means discharges a plurality of droplets discharged onto the passage path of the discharge head in a plurality of times when discharging the droplets of the curable liquid while reciprocating the curable liquid discharge head. The droplets discharged later are means for forming the cross-sectional member by discharging between the previously discharged droplets.

According to this configuration, prior to the modeling of the three-dimensional object, the cross-sectional data at each layer when the three-dimensional object to be modeled is cut into layers in a plurality of cross sections is based on the shape data of the three-dimensional object. Generate. Then, the powder is spread to a substantially uniform thickness to form a powder layer, and droplets of the curable liquid are discharged from the curable liquid discharge head on the powder layer according to the cross-sectional data. When the curable liquid is supplied, the powders are bonded to each other. Therefore, by discharging droplets of the curable liquid onto the powder layer, the cross section has a thickness corresponding to the thickness of the powder layer and has a three-dimensional object. A member having a cross-sectional shape at (
Cross-sectional member) can be formed. Therefore, a new powder layer is formed on the powder layer on which the cross-section member is formed, and a droplet of the curable liquid is ejected to the powder layer according to the cross-section data. And is laminated on the previously formed cross-sectional member. By repeating such an operation, a three-dimensional object can be formed. Here, when forming the cross-sectional member, a plurality of liquid droplets discharged onto the passage path of the curable liquid discharge head are discharged in a plurality of times, and the liquid droplets discharged later are the liquids discharged earlier. A cross-sectional member is formed by discharging between droplets. The liquid droplets ejected later are blocked by the portion of the liquid droplets soaked in the powder layer and cannot spread in the lateral direction. As a result, the liquid droplets penetrate preferentially in the depth direction. It becomes like this. Therefore, the liquid droplets ejected later can be preferentially infiltrated in the depth direction while suppressing the spread in the lateral direction by making the liquid droplets ejected earlier smaller. It is possible to suppress the occurrence of unevenness due to spreading in the lateral direction.

Application Example 3 In the three-dimensional modeling apparatus according to the application example, the cross-sectional member stacking unit includes:
When discharging the curable liquid droplets while reciprocating the curable liquid discharge head, the liquid droplets are discharged to every other position along the moving direction of the curable liquid discharge head, and the cross-sectional member is It is the means to form, It is characterized by the above-mentioned.

In this way, if droplets are ejected to every other position, the later ejected droplets are sandwiched on both sides by the previously ejected droplets. It can be soaked well. In addition, if droplets are ejected to every other position, after all,
The liquid droplets are discharged in two steps. From the viewpoint of modeling a three-dimensional object quickly, it is desirable that the number of droplets ejected is small. In this respect, the number of times of two is the smallest number of times. It is possible to form a smooth surface while minimizing a decrease in the forming speed.

Application Example 4 In the three-dimensional modeling apparatus according to the application example, the cross-sectional member stacking unit includes:
The cross-section member is formed by discharging a droplet of the curable liquid when the curable liquid discharge head moves forward and backward.

According to this configuration, since the curable liquid discharge head discharges the curable liquid droplets while reciprocating on the powder layer, the curable liquid discharge head is supposed to discharge the liquid droplets during forward movement and backward movement. In this case, it is possible to efficiently eject droplets in a short time, and it is possible to quickly form a three-dimensional object.

Application Example 5 In the three-dimensional modeling apparatus according to the application example, the cross-sectional member stacking unit includes:
The cross-section member is formed by discharging droplets of the curable liquid while reciprocating the curable liquid discharge head in a direction crossing the direction in which the powder layer is formed. To do.

According to this configuration, it is possible to form a cross-sectional member by ejecting liquid droplets by reciprocating the curable liquid ejection head immediately behind the end where the powder layer is formed. Therefore, even when the droplets must be ejected from the curable liquid ejection head in a plurality of times in order to form the cross-sectional member, the cross-sectional member can be efficiently formed in a short time, and thus three-dimensional. It becomes possible to form an object quickly.

Application Example 6 In the three-dimensional modeling apparatus according to the application example, the cross-sectional member stacking unit includes:
It is characterized in that a droplet having a larger size than that of the previously ejected droplet is ejected.

According to this configuration, since the size of the liquid droplets ejected first is smaller than the size of the liquid droplets ejected later, the hardening of the powders can be kept in the upper layer of the powder layer body. And promotion of hardening not only in the depth direction but also in the lateral direction can be suppressed.

Application Example 7 In the three-dimensional modeling apparatus according to the application example, the cross-sectional member stacking unit includes a curing rate control unit that controls a curing rate of the curable liquid discharged to the powder layer. And

According to this configuration, the curing rate of the curable liquid can be controlled using the curing rate control means, and the properties of the modeled object can be made uniform.

Application Example 8 In the three-dimensional modeling apparatus according to the application example described above, the curable liquid is an electromagnetic wave curable liquid that is cured by irradiation with electromagnetic waves, and the curing speed control unit is configured such that the electromagnetic wave curable liquid adheres to the powder. It has the electromagnetic wave irradiation part which irradiates electromagnetic waves with respect to a layer, It is characterized by the above-mentioned.

According to this configuration, the curing rate of the curable liquid can be controlled by controlling the electromagnetic wave irradiated from the electromagnetic wave irradiation unit.

Application Example 9 In the three-dimensional modeling apparatus according to the application example, the curing rate control unit includes:
Furthermore, a suppression member that suppresses transmission of the electromagnetic wave is provided between the electromagnetic wave irradiation unit and the powder layer.

According to this configuration, the irradiation amount of the electromagnetic wave can be easily adjusted by the suppressing member.

Application Example 10 In the three-dimensional modeling apparatus according to the application example, the curable liquid is an ultraviolet light curable liquid that is cured by irradiation with ultraviolet light, and the curing speed control unit has the ultraviolet light curable liquid attached thereto. An ultraviolet light irradiation unit that irradiates the powder layer with ultraviolet light, and further includes a suppression member that suppresses transmission of the ultraviolet light between the ultraviolet light irradiation unit and the powder layer. It is characterized by that.

According to this configuration, for example, the curing rate is controlled by controlling the irradiation amount of ultraviolet light irradiated from the ultraviolet light irradiation unit and further easily adjusting the irradiation amount of ultraviolet light by the suppressing member. be able to.

Application Example 11 In the three-dimensional modeling apparatus according to the application example, the curing liquid is a thermosetting liquid that is cured by heating, and the curing speed control unit is configured to apply the powder to which the thermosetting liquid is attached. It has the heating part which heats a layer, It is characterized by the above-mentioned.

According to this configuration, for example, the curing rate can be controlled by controlling the heating temperature.

Application Example 12 In the three-dimensional modeling apparatus according to the application example, the curing speed control unit is the curable liquid discharged from the curable liquid discharge head, and the curable liquid discharged later is
A curable liquid having a slower curing speed than the previously discharged curable liquid is discharged as droplets.

According to this configuration, since the curable liquid discharged earlier and the curable liquid discharged later in the powder layer are cured at the same time, it is possible to control the curing speed and to suppress variations in the curing speed. .

[Application Example 13] A three-dimensional modeling method according to this application example is a three-dimensional modeling method for modeling a three-dimensional object by bonding powders together with a curing liquid, and the powder is formed to have a substantially uniform thickness. Based on the shape data of the three-dimensional object, the powder layer forming step of forming a powder layer by spreading the layer, and the cross-sectional data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross-sections A cross-section data generating step generated in accordance with the cross-sectional data, and discharging the liquid droplets toward the powder layer from a curable liquid discharge head provided with a discharge nozzle for discharging the curable liquid droplets according to the cross-section data. A cross-sectional member laminating step for forming a cross-sectional member in which the powders of the body layers are bonded to each other, and in the cross-sectional member laminating step, while controlling the speed of soaking into the powder layer of the discharged curable liquid Cross section And forming a.

According to this configuration, prior to the modeling of the three-dimensional object, the cross-sectional data at each layer when the three-dimensional object to be modeled is cut into layers in a plurality of cross sections is based on the shape data of the three-dimensional object. Generate. Then, the powder is spread to a substantially uniform thickness to form a powder layer, and droplets of the curable liquid are discharged from the curable liquid discharge head on the powder layer according to the cross-sectional data. When the curable liquid is supplied, the powders are bonded to each other. Therefore, by discharging droplets of the curable liquid onto the powder layer, the cross section has a thickness corresponding to the thickness of the powder layer and has a three-dimensional object. A member having a cross-sectional shape at (
Cross-sectional member) can be formed. Therefore, a new powder layer is formed on the powder layer on which the cross-section member is formed, and a droplet of the curable liquid is ejected to the powder layer according to the cross-section data. And is laminated on the previously formed cross-sectional member. By repeating such an operation, a three-dimensional object can be formed. Here, the cross-sectional member is formed while controlling the speed of penetration of the curable liquid discharged from the curable liquid discharge head into the powder layer. Therefore, by controlling the permeation speed, it is possible to suppress the occurrence of unevenness on the surface portion of the three-dimensional object.

Application Example 14 In the three-dimensional modeling method according to the application example described above, a powder layer forming step of forming a powder layer by spreading the powder to a substantially uniform thickness, and the three-dimensional object having a plurality of cross sections A cross-section data generation step for generating cross-sectional data obtained in each layer when the layer is cut into layers based on the shape data of the three-dimensional object, and a curable liquid provided with a discharge nozzle for discharging droplets of the curable liquid By discharging droplets toward the powder layer according to the cross-sectional data while reciprocating the powder head on the powder layer, a cross-section member in which the powders of the powder layer are combined is formed. And a cross-sectional member laminating step of laminating the cross-sectional member on the cross-sectional member formed in the lower layer, wherein the cross-sectional member laminating step reciprocally moves the curable liquid discharge head. Eject droplets In this case, a plurality of droplets discharged onto the passage path of the discharge head are discharged in a plurality of times, and the droplets discharged later are discharged between the previously discharged droplets. It is a process of forming a cross-sectional member.

According to this configuration, prior to the modeling of the three-dimensional object, the cross-sectional data at each layer when the three-dimensional object to be modeled is cut into layers in a plurality of cross sections is based on the shape data of the three-dimensional object. Generate. Then, the powder is spread to a substantially uniform thickness to form a powder layer, and droplets of the curable liquid are discharged from the curable liquid discharge head on the powder layer according to the cross-sectional data. When the curable liquid is supplied, the powders are bonded to each other. Therefore, by discharging droplets of the curable liquid onto the powder layer, the cross section has a thickness corresponding to the thickness of the powder layer and has a three-dimensional object. A member having a cross-sectional shape at (
Cross-sectional member) can be formed. Therefore, a new powder layer is formed on the powder layer on which the cross-section member is formed, and a droplet of the curable liquid is ejected to the powder layer according to the cross-section data. And is laminated on the previously formed cross-sectional member. By repeating such an operation, a three-dimensional object can be formed. Here, when forming the cross-sectional member, a plurality of liquid droplets discharged onto the passage path of the curable liquid discharge head are discharged in a plurality of times, and the liquid droplets discharged later are the liquids discharged earlier. A cross-sectional member is formed by discharging between droplets. The liquid droplets ejected later are blocked by the portion of the liquid droplets soaked in the powder layer and cannot spread in the lateral direction. As a result, the liquid droplets penetrate preferentially in the depth direction. It becomes like this. Therefore, the liquid droplets ejected later can be preferentially infiltrated in the depth direction while suppressing the spread in the lateral direction by making the liquid droplets ejected earlier smaller. It is possible to suppress the occurrence of unevenness due to spreading in the lateral direction.

Application Example 15 In the three-dimensional modeling method according to the application example, in the cross-sectional member stacking step, when the curable liquid droplet is discharged while the curable liquid discharge head is reciprocated, the curable liquid discharge head is used. The cross-sectional member is formed by ejecting droplets to every other position along the moving direction of.

In this way, if droplets are ejected to every other position, the later ejected droplets are sandwiched on both sides by the previously ejected droplets. It can be soaked well. In addition, if droplets are ejected to every other position, after all,
The liquid droplets are discharged in two steps. From the viewpoint of modeling a three-dimensional object quickly, it is desirable that the number of droplets ejected is small. In this respect, the number of times of two is the smallest number of times. It is possible to form a smooth surface while minimizing a decrease in the forming speed.

[Application Example 16] In the three-dimensional modeling method according to the application example, in the cross-section member stacking step, the curable liquid droplets are discharged during forward movement and backward movement of the curable liquid discharge head, and A cross-sectional member is formed.

According to this configuration, since the curable liquid discharge head discharges the curable liquid droplets while reciprocating on the powder layer, the curable liquid discharge head is supposed to discharge the liquid droplets during forward movement and backward movement. In this case, it is possible to efficiently eject droplets in a short time, and it is possible to quickly form a three-dimensional object.

Application Example 17 In the three-dimensional modeling method according to the application example, in the cross-sectional member stacking step, the curing liquid discharge head is reciprocated in a direction crossing the direction in which the powder layer is formed, and the curing is performed. The cross-sectional member is formed by discharging liquid droplets.

According to this configuration, it is possible to form a cross-sectional member by ejecting liquid droplets by reciprocating the curable liquid ejection head immediately behind the end where the powder layer is formed. Therefore, even when the droplets must be ejected from the curable liquid ejection head in a plurality of times in order to form the cross-sectional member, the cross-sectional member can be efficiently formed in a short time, and thus three-dimensional. It becomes possible to form an object quickly.

Application Example 18 In the three-dimensional modeling method according to the application example described above, in the cross-sectional member stacking step, the size of the liquid droplet ejected later is larger than the size of the liquid droplet ejected earlier. It is characterized by discharging.

According to this configuration, since the size of the liquid droplet ejected first is smaller than the size of the liquid droplet ejected later, the hardening of the powders can be kept in the upper layer of the powder layer body. And promotion of hardening not only in the depth direction but also in the lateral direction can be suppressed.

Application Example 19 In the three-dimensional modeling method according to the application example, in the cross-sectional member stacking step, the cross-sectional member is formed while controlling a curing rate of the curable liquid discharged to the powder layer. And

According to this configuration, by controlling the curing rate, it is possible to make the properties of the modeled object uniform.

[Application Example 20] In the three-dimensional modeling method according to the application example, in the cross-section member stacking step, the powder layer to which the electromagnetic wave curable liquid that is cured by irradiation with electromagnetic waves is discharged as droplets and the electromagnetic wave curable liquid is attached. It is characterized by irradiating an electromagnetic wave with respect to.

According to this configuration, for example, the curing rate of the curable liquid can be controlled by controlling the irradiation amount of the irradiated electromagnetic wave.

[Application Example 21] In the three-dimensional modeling method according to the application example described above, in the cross-section member stacking step, the ultraviolet light curable liquid that is cured by irradiation with ultraviolet light is discharged as droplets, and the ultraviolet light curable liquid is attached. The powder layer is irradiated with ultraviolet light.

According to this configuration, for example, the curing rate of the curable liquid can be controlled by controlling the irradiation amount of the irradiated ultraviolet light.

[Application Example 22] In the three-dimensional modeling method according to the application example, in the cross-sectional member stacking step, a thermosetting liquid that is cured by heating is discharged as droplets, and the powder layer to which the thermosetting liquid is attached is heated. It is characterized by doing.

According to this configuration, for example, the curing rate can be controlled by controlling the heating temperature.

[Application Example 23] In the three-dimensional modeling method according to the application example, in the cross-sectional member stacking step, the curable liquid discharged later is a curable liquid having a slower curing speed than the previously discharged curable liquid as droplets. It is characterized by discharging.

According to this configuration, since the curable liquid discharged earlier and the curable liquid discharged later in the powder layer are cured at the same time, the curing rate can be controlled.

[First Embodiment]
Below, in order to clarify the content of 1st Embodiment concerning this invention mentioned above, it demonstrates in order as follows.
A-1. Device configuration in the first embodiment:
B-1. Modeling method in the first embodiment:

A-1. Device configuration in the first embodiment:
FIG. 1 is an explanatory diagram showing a rough configuration of the three-dimensional modeling apparatus 100 of the present embodiment. As shown in the figure, the three-dimensional modeling apparatus 100 includes a modeling unit 10 that is configured by a large frame and in which a three-dimensional object is modeled, and a powder that forms a powder layer of powder in the modeling unit 10. The layer forming unit 20, the curable liquid supply unit 30 for supplying a curable liquid for bonding powders to the powder layer, and the ultraviolet for irradiating the curable liquid supplied to the powder layer with ultraviolet light to cure the curable liquid. The light irradiation unit 50 and an arithmetic processing unit 40 that performs various arithmetic processes to control the entire operation of the three-dimensional modeling apparatus 100 are configured.

The arithmetic processing unit 40 stores shape data of a three-dimensional object to be modeled, and cuts the three-dimensional object into a plurality of cross sections to generate cross section data in each layer. And a control unit 44 for controlling the operation of the modeling unit 10, the powder layer forming unit 20, the curable liquid supply unit 30, and the like according to the obtained cross-sectional data. When the control unit 44 receives the cross-section data from the cross-section data generation unit 42, the control unit 44 drives the powder layer forming unit 20 to form a powder layer in the modeling unit 10, and drives the curable liquid supply unit 30 to drive the curable liquid. Is supplied to the powder layer according to the cross-sectional data, and ultraviolet light is irradiated toward the supplied curable liquid. Then, the curable liquid is cured by ultraviolet light and the powders are bonded to each other, whereby a thin plate-like member (cross-sectional member) having a cross-sectional shape corresponding to the cross-sectional data for one layer is formed in the modeling portion 10. The When the cross-sectional member for one layer is formed in this way, the bottom surface driving unit 16 is driven to slightly lower the bottom surface unit 14. Next, the next cross-section data is received from the cross-section data generation unit 42, a new powder layer is formed on the powder layer on which the cross-section member is formed, and a curable liquid is supplied from above to irradiate ultraviolet light. By
A new cross-sectional member is formed. As described above, when the control unit 44 receives the cross-section data of each layer from the cross-section data generation unit 42, the control unit 44 drives the modeling unit 10, the powder layer forming unit 20, the curable liquid supply unit 30, and the ultraviolet light irradiation unit 50. The cross-sectional members are formed and stacked one by one.

The cross-section data generation unit 42 can be configured using a known computer in which a CPU, a ROM, a RAM, a hard disk, and the like are configured to exchange data with each other.
Further, the control unit 44 can be configured using a dedicated IC chip that converts the cross-sectional data and generates a drive signal to the modeling unit 10, the powder layer forming unit 20, and the curable liquid supply unit 30. Of course, such conversion may be performed using a CPU, ROM, RAM, or the like. In this case, it is also possible to incorporate the function of the control unit 44 into the computer constituting the cross-section data generation unit 42 so that the cross-section data generation unit 42 and the control unit 44 are integrally configured.

The modeling unit 10 includes a frame body 12 that is rectangular when viewed from above, a bottom surface part 14 that forms the bottom surface of the frame body 12 and is slidable in the vertical direction, and a bottom surface that slides the bottom surface part 14 in the vertical direction. Drive unit 16
The three-dimensional object is formed in a space formed between the frame body 12 and the bottom surface portion 14. Further, the bottom surface driving unit 16 can accurately move the bottom surface portion 14 in the vertical direction under the control of the control unit 44.

The powder layer forming unit 20 is supplied from a hopper 22 in which powder is stored, a powder supply roller 24 that supplies powder by a fixed amount by rotating at a lower portion of the hopper 22, and a powder supply roller 24. The extending roller 26 is configured to extend the powder to a certain thickness to form a powder layer. The hopper 22, the powder supply roller 24, and the extension roller 26 are formed so as to extend in a direction perpendicular to the paper surface of FIG. 1 (Y direction), and the powder layer forming unit 20 is entirely on the paper surface of FIG. 1. It can be moved in the left-right direction (X direction).

When forming the powder layer, first, the powder layer forming unit 20 is moved to the left end of FIG.
At this time, the bottom surface driving portion 16 is driven by an amount corresponding to the thickness of the powder layer to be formed, and the bottom surface portion 1 is driven.
The position of 4 is lowered downward (minus Z direction). Then, the powder supply roller 24 is rotated to move the powder layer forming unit 20 in the right direction (plus X direction) while supplying the powder in front of the extension roller 26. The extension roller 26 is rotated in the reverse direction with respect to the traveling direction. In this way, the extension roller 26 moves while kicking excess powder in the direction of travel, and as a result, a powder layer having a uniform thickness is formed behind. At this time,
The supply rate of the powder depends on the thickness of the powder layer to be formed and the moving speed of the powder layer forming unit 20.
Controlled to an appropriate feed rate. Further, the rotation speed of the extension roller 26 depends on the powder layer forming unit 2.
The rotation speed is controlled appropriately according to the moving speed of zero. In this way, it is possible to kick out excess powder in the direction of travel and always extend the powder by an appropriate amount, and as a result, it is possible to avoid excessively treading the powder. It becomes possible.

The curable liquid supply unit 30 includes a discharge head that discharges droplets of the curable liquid, a storage unit that stores the curable liquid, and the like. The curable liquid supply unit 30 receives the curable liquid droplets stored in the curable liquid storage unit 34. The curable liquid discharge head 32 can discharge toward the powder layer.

Here, as the curable liquid discharge head 32 of the present embodiment, a so-called piezoelectric drive type liquid droplet discharge head is employed. The piezo drive type droplet discharge head is equivalent to the volume reduction of the pressure chamber by filling the pressure chamber with fine nozzle holes with liquid and bending the side wall of the pressure chamber using a piezo element. It is possible to discharge a volume of liquid as droplets. In the curable liquid supply part 30 of the present embodiment, the curable liquid stored in the curable liquid storage part 34 is guided to the pressure chamber of the curable liquid discharge head 32 to drive the piezo element, whereby the liquid curable liquid is obtained. It is possible to discharge.

Here, as the curable liquid, a liquid resin material mainly composed of a monomer and an oligomer to which the monomer is bonded, and a polymerization that activates the monomer or oligomer when it is irradiated with ultraviolet light and starts polymerization. Mixtures with initiators are used. In addition, a monomer having a relatively low molecular weight is selected as the monomer of the curable liquid so that it can be discharged as droplets from a piezo-driven droplet discharge head, and is further included in one oligomer. The number of monomers is also adjusted to about several molecules. Since the curable liquid is stable as long as it is not exposed to ultraviolet light, it can be discharged as droplets without being cured inside the curable liquid container 34 or the curable liquid discharge head 32. When the polymerization initiator is brought into an excited state by being bathed, the monomers are polymerized with each other to grow into oligomers, and the oligomers are also polymerized in some places and quickly cured to become a solid.

In addition, a different type of polymerization initiator than that contained in the curable liquid is attached to the surface of the powder. The polymerization initiator attached to the surface of the powder has the property of initiating polymerization by acting on a monomer or oligomer when it comes into contact with the curable liquid. For this reason, when a droplet of the curable liquid is supplied to the powder layer, the curable liquid penetrates into the powder layer and is cured by contact with the polymerization initiator on the powder surface. As a result, the curable liquid is discharged. In the part which was done, it will be in the state couple | bonded by the hardening | curing liquid with which powder was hardened | cured.

Further, the curable liquid discharge head 32 is controlled by the control unit 44, independently of the powder layer forming unit 20, in the X direction (left and right direction on the paper surface of FIG. 1) and the Y direction (the paper surface of FIG. 1). In the vertical direction). This point will be described later with reference to another drawing.

The ultraviolet light irradiation unit 50 surrounds the three sides of the elongated ultraviolet light irradiation lamp provided along the Y direction (perpendicular to the paper surface of FIG. 1) and the ultraviolet light irradiation lamp so that the ultraviolet light is irradiated only downward. An ultraviolet light shielding member is used. The ultraviolet light irradiation unit 50 is turned on or off under the control of the control unit 44, and moves in the X direction (left and right direction on the paper surface of FIG. 1) together with the powder layer forming unit 20 and the curable liquid supply unit 30. Thus, it is possible to uniformly irradiate ultraviolet light over the entire surface of the powder layer.

FIG. 2 is a perspective view illustrating a positional relationship in which the powder layer forming unit 20, the curable liquid discharge head 32, and the ultraviolet light irradiation unit 50 are mounted in the three-dimensional modeling apparatus 100 of the present embodiment. As shown in FIG. 2A, the powder layer forming unit 20 and the ultraviolet light irradiation unit 50 are formed long in the Y direction, and are located between the powder layer forming unit 20 and the ultraviolet light irradiation unit 50. Is mounted with a curable liquid discharge head 32. The curable liquid discharge head 32 is configured to reciprocate in the Y direction, and a discharge head for discharging droplets of the curable liquid is provided on the bottom surface side (powder layer side) of the curable liquid discharge head 32. ing. FIG. 2B shows a state where the discharge nozzle 32 n is provided on the bottom surface side of the curable liquid discharge head 32. As shown in the figure, the curable liquid discharge head 32.
A plurality of discharge nozzles 32n are provided at regular intervals on the bottom surface of the, and the droplets of the curable liquid are discharged onto the plurality of lines by discharging the droplets while moving the curable liquid discharge head 32 in the Y direction. Can be discharged.

FIG. 3 is an explanatory diagram conceptually showing a state in which a 3D object is modeled by the 3D modeling apparatus 100 of the present embodiment having the above-described configuration. In modeling a three-dimensional object, it is necessary to store three-dimensional shape data of the object to be modeled in advance. FIG. 3A conceptually represents shape data of a three-dimensional object to be modeled. In the example shown in FIG. 3 (a), the three-dimensional object to be shaped has a tea tube shape with a slightly narrowed center, and large round windows are formed in the center of the upper and lower surfaces of the tea tube shape. ing. And the partition plate which partitions off the inside of a tea cylinder shape up and down is provided in the inside of a tea cylinder shape. When such a three-dimensional object is cut into layers in a plurality of cross sections parallel to the upper surface (or lower surface), cross-sectional data as shown in FIG. 3B can be obtained. In addition, although the space | interval which takes a cross section does not necessarily need to be equal intervals, it shall be equal intervals here. These processes are performed by the cross-section data generation unit 42.
The obtained cross-sectional data is supplied to the control unit 44.

The control unit 44 drives the modeling unit 10 and the powder layer forming unit 20 to form a powder layer, and drives the curable liquid discharge head 32 according to the cross-section data received from the cross-section data generation unit 42 to A droplet of curable liquid is ejected onto the layer. As described above, the curable liquid ejection head 32 that ejects droplets employs a piezo drive type droplet ejection head that is also used in an ink jet printer, and is accurately controlled by the control unit 44 in the X and Y directions. Droplets can be discharged while positioning. For this reason, it is possible to form a cross-section member as shown in the cross-section data by discharging the curable liquid to an accurate position on the surface of the powder layer according to the cross-section data, and the cross-section member can be formed by repeating these operations. By stacking, the three-dimensional object corresponding to the three-dimensional shape data can be formed.

However, since the droplets discharged to the powder layer try to spread not only in the depth direction but also in the surroundings, irregularities are formed on the surface of the shaped three-dimensional object. If the size of the droplet is reduced to suppress the spread to the surroundings, the penetration in the depth direction is also suppressed, so that the cross-sectional members cannot be joined. In view of these points, the three-dimensional modeling apparatus 100 of the present embodiment enables modeling of a three-dimensional object having a smooth surface by discharging droplets by the following method.

B-1. Modeling method in the first embodiment:
For convenience of understanding, first, a case where droplets are ejected by a general method will be briefly described. FIG. 4 is an explanatory view conceptually showing how a three-dimensional object is shaped by discharging droplets onto a powder layer by a general method. The figure shows a state in which a powder layer is formed on a cross-sectional member in which powder is hardened with a curable liquid, and droplets of the curable liquid are ejected by the curable liquid ejection head 32 from the powder layer. When the ejected liquid droplets land on the surface of the powder layer, the liquid droplets soak into the depth direction and the periphery thereof. In addition, as described above, since the polymerization initiator is applied to the surface of the powder, the hardening liquid penetrates into the powder layer, and the polymerization starts from the part of the powder surface that touches the polymerization initiator. To do. In FIG. 4, the portion where the droplet of the curable liquid first landed and soaked is shown in black, and the portion spread around it is shown with fine diagonal lines, and further around that portion The expanded part is shown with a rough diagonal line.

When the liquid droplets of the curable liquid soak into the powder layer, the effect of gravity is slightly affected, but mainly the liquid droplets are soaked into the gap between the powders by capillary action. As shown in FIG. 4, the ink penetrates into a substantially hemispherical shape with the landing position as the center. Then, in order to firmly bond the powder layer formed on the uppermost surface to the cross-sectional member formed on the lower side, the curing liquid spreads to the bottom surface of the powder layer (the upper surface of the lower cross-sectional member). In addition, large droplets must be discharged. As a result, the permeation into the surrounding area also increases, and irregularities occur on the surface. If the curable liquid can be selectively infiltrated in the downward direction, it is possible to suppress unevenness generated on the surface. However, the phenomenon that the curable liquid penetrates is caused by capillary action in the gaps between the powders. Is mainly governed by the phenomenon of sucking, and it is extremely difficult to control the gap formed between the powders. Therefore, the three-dimensional modeling apparatus 100 of the present embodiment discharges the curable liquid by the following method.

FIG. 5 is an explanatory view conceptually showing a state in which the three-dimensional modeling apparatus 100 of the present embodiment forms a three-dimensional object by discharging droplets onto the powder layer. As shown in the drawing, in the three-dimensional modeling apparatus 100 of the present embodiment, the liquid droplets are ejected in a plurality of times. By doing so, it becomes possible to preferentially infiltrate the curable liquid in the downward direction for the reason explained below, and as a result, the unevenness generated on the surface by the amount of infiltration in the lateral direction is suppressed. It can be made smaller. Hereinafter, a detailed description will be given with reference to FIG.

In the three-dimensional modeling apparatus 100 of the present embodiment, as shown in FIG. 5A, first, droplets are ejected to the jumping position (that is, in a thinned state). The droplets ejected at this time do not need to penetrate to the lower surface of the powder layer, and it is sufficient to eject small droplets. As described above, the discharged droplets are sucked into the gap between the powders by capillary action,
It spreads in a substantially hemispherical shape, and the polymerization is started by touching the polymerization initiator applied to the powder surface. FIG. 5A shows a state in which small droplets are discharged in this way and penetrate into the powder layer.

Next, a droplet is ejected to a position during which the droplet has been ejected first. FIG. 5B conceptually shows a state in which a new droplet is ejected at a position during which the droplet has been ejected first. As described with reference to FIG. 5 (a), the previously ejected droplets soaked into the powder layer and started polymerization,
It is in a state of being almost solidified. In FIG.5 (b), the part which the hardening | curing liquid discharged previously half-set in the powder layer is represented by attaching | subjecting a grid-like hatching. The lattice hatched part is filled with the gaps between the powders, so that the liquid droplets discharged later cannot penetrate this part, and as a result, the lower part is given priority. Soak up. As a result, the curable liquid discharged later quickly reaches the lower surface of the powder layer, and also penetrates below the portion where the previously discharged liquid droplets have been solidified. A cross-sectional member is formed and laminated on the previously formed cross-sectional member.

In the modeling method of the present embodiment described above, the droplets that can be formed while the curable liquid discharge head 32 moves once on the powder layer are divided into a plurality of times (twice in the above embodiment). For example, even if the lower surface of the powder layer cannot be cured by the first ejected droplets, it is only necessary that the droplets can be cured by the later ejected droplets. For this reason, since the droplet discharged initially can be made into a small droplet, it can suppress that the discharged hardening liquid osmose | permeates to a horizontal direction. Next, since the liquid droplets ejected later are obstructed by the liquid droplets ejected earlier, they cannot spread so much in the lateral direction, and as a result, they penetrate preferentially in the depth direction. Eventually, the droplets that are ejected at the beginning spread in the horizontal direction as well as the depth direction, but the droplets that are ejected later are suppressed in the lateral direction, giving priority to the depth direction. As a whole, the liquid droplets can be preferentially soaked in the depth direction. As a result, the unevenness formed on the surface of the three-dimensional object can be suppressed, and a three-dimensional object having a smooth surface can be formed.

[Second Embodiment]
Next, the contents of the second embodiment will be described in the following order. In the present embodiment, control of the curing rate of the curable liquid will be mainly described.
A-2. Device configuration in the second embodiment:
B-2. Modeling method in the second embodiment:

A-2. Device configuration in the second embodiment:
FIG. 6 is an explanatory diagram showing a rough configuration of the three-dimensional modeling apparatus 110 of the present embodiment. As shown in the figure, the three-dimensional modeling apparatus 110 includes a modeling unit 10 that is configured from a large frame and in which a three-dimensional object is modeled, and a powder that forms a powder layer of powder in the modeling unit 10. A layer forming part 20, a hardening liquid supply part 30 for supplying a hardening liquid for bonding powders to the powder layer, a hardening speed control means for controlling the hardening speed of the hardening liquid supplied to the powder layer, and tertiary In order to control the entire operation of the original modeling apparatus 110, the processing apparatus 40 includes an arithmetic processing unit 40 that performs various arithmetic processes.

In the present embodiment, an ultraviolet light curable liquid that is cured by irradiation with ultraviolet light will be described as an example of the curable liquid. And as a curing rate control means, the ultraviolet light irradiation part 50 which irradiates ultraviolet light to ultraviolet light hardening liquid, and the suppression which suppresses transmission of ultraviolet light provided between the ultraviolet light irradiation part 50 and a powder layer. The three-dimensional modeling apparatus 110 provided with the member 70 will be described as an example.

The arithmetic processing unit 40 stores shape data of a three-dimensional object to be modeled, and cuts the three-dimensional object into a plurality of cross sections to generate cross section data in each layer. And the control part 4 which controls operation | movement of the modeling part 10, the powder layer formation part 20, the hardening liquid supply part 30, the ultraviolet light irradiation part 50, and the suppression member 70 according to the cross-sectional data obtained by the ultraviolet light irradiation part 50.
4 or the like. When the control unit 44 receives the cross-section data from the cross-section data generation unit 42, the control unit 44 drives the powder layer forming unit 20 to form a powder layer in the modeling unit 10, and the curable liquid supply unit 30.
Is driven to irradiate ultraviolet light from the ultraviolet light irradiation unit 50 toward the supplied ultraviolet light curable liquid while supplying the ultraviolet light curable liquid to the powder layer according to the cross-sectional data. When the irradiated ultraviolet light is irradiated to the powder layer, the ultraviolet light curable liquid is cured and the powders are bonded to each other, so that the cross section corresponding to the cross section data for one layer is formed in the modeling unit 10. A thin plate-shaped member (cross-sectional member) having a shape is formed. When the cross-sectional member for one layer is formed in this way, the bottom surface driving unit 16 is driven to slightly lower the bottom surface unit 14. Next, the next cross-section data is received from the cross-section data generation unit 42, a new powder layer is formed on the powder layer on which the cross-section member is formed, and an ultraviolet light curable liquid is supplied from above to generate ultraviolet light. A new cross-sectional member is formed by irradiation. Thus, the control unit 44
When the cross-section data of each layer is received from the cross-section data generation unit 42, the modeling unit 10, the powder layer forming unit 20, the curable liquid supply unit 30, the ultraviolet light irradiation unit 50, and the suppression member 70 are driven one layer at a time. Cross-section members are formed and stacked.

The cross-section data generation unit 42 can be configured using a known computer in which a CPU, a ROM, a RAM, a hard disk, and the like are configured to exchange data with each other. Further, the control unit 44 can be configured using a dedicated IC chip that converts the cross-sectional data and generates a drive signal to the modeling unit 10, the powder layer forming unit 20, and the curable liquid supply unit 30. Of course, such conversion may be performed using a CPU, ROM, RAM, or the like. In this case, it is also possible to incorporate the function of the control unit 44 into the computer constituting the cross-section data generation unit 42 so that the cross-section data generation unit 42 and the control unit 44 are integrally configured.

The modeling unit 10 includes a frame body 12 that is rectangular when viewed from above, a bottom surface part 14 that forms the bottom surface of the frame body 12 and is slidable in the vertical direction, and a bottom surface that slides the bottom surface part 14 in the vertical direction. Drive unit 16
The three-dimensional object is formed in a space formed between the frame body 12 and the bottom surface portion 14. Further, the bottom surface driving unit 16 can accurately move the bottom surface portion 14 in the vertical direction under the control of the control unit 44.

The powder layer forming unit 20 is supplied from a hopper 22 in which powder is stored, a powder supply roller 24 that supplies powder by a fixed amount by rotating at a lower portion of the hopper 22, and a powder supply roller 24. The extending roller 26 is configured to extend the powder to a certain thickness to form a powder layer. The hopper 22, the powder supply roller 24, and the extension roller 26 are formed so as to extend in a direction perpendicular to the paper surface of FIG. 6 (Y direction), and the powder layer forming portion 20 is entirely on the paper surface of FIG. It can be moved in the left-right direction (X direction).

When forming the powder layer, first, the powder layer forming unit 20 is moved to the left end of FIG.
At this time, the bottom surface driving portion 16 is driven by an amount corresponding to the thickness of the powder layer to be formed, and the bottom surface portion 1 is driven.
The position of 4 is lowered downward (minus Z direction). Then, the powder supply roller 24 is rotated to move the powder layer forming unit 20 in the right direction (plus X direction) while supplying the powder in front of the extension roller 26. The extension roller 26 is rotated in the reverse direction with respect to the traveling direction. In this way, the extension roller 26 moves while kicking excess powder in the direction of travel, and as a result, a powder layer having a uniform thickness is formed behind. At this time,
The supply rate of the powder depends on the thickness of the powder layer to be formed and the moving speed of the powder layer forming unit 20.
Controlled to an appropriate feed rate. Further, the rotation speed of the extension roller 26 depends on the powder layer forming unit 2.
The rotation speed is controlled appropriately according to the moving speed of zero. In this way, it is possible to kick out excess powder in the direction of travel and always extend the powder by an appropriate amount, and as a result, it is possible to avoid excessively treading the powder. It becomes possible.

The curable liquid supply unit 30 includes a head unit 60 having a plurality of curable liquid discharge heads 61 (see FIG. 8), a curable liquid storage unit 34 that stores an ultraviolet light curable liquid, and the like. The head unit 61 is provided along the Y direction (perpendicular to the paper surface of FIG. 6). And
It is possible to discharge the ultraviolet light curable liquid droplets stored in the curable liquid storage unit 34 from the curable liquid discharge head 61 toward the powder layer.

Here, as the curable liquid discharge head 61 of the present embodiment, a so-called piezo drive type droplet discharge head is employed. The piezo drive type droplet discharge head is equivalent to the volume reduction of the pressure chamber by filling the pressure chamber with fine nozzle holes with liquid and bending the side wall of the pressure chamber using a piezo element. It is possible to discharge a volume of liquid as droplets. In the curable liquid supply unit 30 of the present embodiment, the ultraviolet light curable liquid stored in the curable liquid storage unit 34 is
By driving the piezo element by guiding it to the pressure chamber of the curable liquid discharge head 61, it is possible to discharge a droplet-like ultraviolet light curable liquid.

Here, as the ultraviolet light curable liquid, a liquid resin material mainly composed of a monomer and an oligomer to which the monomer is bonded, and when irradiated with ultraviolet light, it becomes excited and acts on the monomer or oligomer to start polymerization. A mixture with a polymerization initiator to be used is used. In addition, a relatively low molecular weight monomer is selected as the monomer of the ultraviolet light curable liquid so that it can be ejected as droplets from a piezo-driven droplet ejection head. The number of monomers contained is also adjusted to about several molecules. And the ultraviolet curable liquid is
Since it is stable as long as it is not exposed to ultraviolet light, it can be discharged as droplets without being cured inside the curable liquid container 34 or the curable liquid discharge head 61, but the polymerization initiator is exposed to ultraviolet light. When in an excited state, the monomers are polymerized to grow into oligomers, and the oligomers are also polymerized in various places and quickly cured to become a solid.

In addition, a different type of polymerization initiator from that contained in the ultraviolet light curable liquid is attached to the surface of the powder. The polymerization initiator attached to the surface of the powder has a property of initiating polymerization by acting on the monomer or oligomer when it comes into contact with the ultraviolet light curable liquid. For this reason, when a droplet of the ultraviolet light curable liquid is supplied to the powder layer, the ultraviolet light curable liquid penetrates into the powder layer and is cured by contact with the polymerization initiator on the powder surface. In the portion where the ultraviolet curable liquid is discharged, the powders are bonded by the cured ultraviolet light curable liquid.

Further, the curable liquid discharge head 61 can be moved in the X direction (left and right direction on the paper surface of FIG. 6) independently of the powder layer forming unit 20 under the control of the control unit 44. ing. This point will be described later with reference to another drawing.

The ultraviolet light irradiation unit 50 surrounds the three sides of the elongated ultraviolet light irradiation lamp provided along the Y direction (perpendicular to the paper surface of FIG. 6) and the ultraviolet light irradiation lamp so that the ultraviolet light is irradiated only downward. An ultraviolet light shielding member is used. The ultraviolet light irradiation unit 50 is turned on or off under the control of the control unit 44, and moves in the X direction (left and right direction on the paper surface of FIG. 6) together with the powder layer forming unit 20 and the curable liquid supply unit 30. Thus, it is possible to uniformly irradiate ultraviolet light over the entire surface of the powder layer.

The suppression member 70 is a member that suppresses transmission of ultraviolet light. For example, the suppression member 70 is a plastic material containing oxides such as titanium oxide and zinc oxide, benzotriazole series, hindered amine series, etc., or carbon, black that easily absorbs light. A plastic material containing a pigment can be used. Moreover, the member which provides an unevenness | corrugation in the surface of the suppression member 70, and reflects an ultraviolet light may be sufficient. Furthermore, the ultraviolet light suppressing member 70 is provided between the ultraviolet light irradiation unit 50 and the powder layer. In the present embodiment, the suppressing member 70 is a plate-like member that is large enough to cover the ultraviolet light shielding member along the Y direction (the direction perpendicular to the paper surface of FIG. 6). And it can move to X direction (left-right direction on the paper surface of FIG. 6) with the ultraviolet light irradiation part 50 by control from the control part 44. FIG. Further, the restraining member 70 is provided with an openable / closable opening / closing section, and the opening / closing section is opened / closed under the control of the control section 44. And if the open / close part is closed,
If the transmission of the ultraviolet light irradiated from the ultraviolet light irradiation unit 50 is suppressed and the opening / closing unit is in an open state, the powder layer is irradiated with the ultraviolet light through the opening. In the present embodiment, a plurality of opening / closing portions are provided at predetermined positions of the suppressing member 70, and the opening / closing of the opening / closing portions is controlled by the control unit 44.
It is opened and closed by the control from.

FIG. 7 is a perspective view illustrating a positional relationship in which the powder layer forming unit 20, the head unit 60, the ultraviolet light irradiation unit 50, and the suppressing member 70 are mounted in the three-dimensional modeling apparatus 110 of the present embodiment. is there. As shown in FIG. 7, the powder layer forming unit 20 and the ultraviolet light irradiation unit 50 are Y
The head unit 60 is mounted between the powder layer forming unit 20 and the ultraviolet light irradiation unit 50. The head unit 60 is formed long in the Y direction,
The ultraviolet curable liquid can be discharged to the region of the powder layer in the Y direction without reciprocating in the Y direction. FIG. 8 shows a state of the head unit 60 as viewed from the plane. The head unit 60 includes a plurality of curable liquid discharge heads 61, and the curable liquid discharge head 61 is provided with a plurality of discharge nozzles 61n. As shown in the figure, the curable liquid discharge head 61 is provided with a plurality of discharge nozzles 61n at regular intervals, and the ultraviolet light curable liquid is applied to a wide area in one discharge operation on the powder layer. Can do.

Since the data processing of the three-dimensional object for modeling the three-dimensional object by the three-dimensional modeling apparatus 110 of the present embodiment having the above-described configuration is the same as that of the first embodiment (see FIG. 3), the description thereof is omitted.

In the modeling of a three-dimensional object, the properties of the three-dimensional object may change due to variations in the curing rate of the ultraviolet light curable liquid, which may cause cracking or deformation. In view of these points, the three-dimensional modeling apparatus 110 of the present embodiment enables a three-dimensional modeling method for controlling the curing rate of the ultraviolet light curable liquid.

B-2. Modeling method in the second embodiment:
Since a general modeling method is the same as the description in Embodiment 1 (see FIG. 4), the description is omitted.

FIG. 9 is an explanatory view conceptually showing a state in which the three-dimensional modeling apparatus 110 of the present embodiment forms a three-dimensional object by discharging the ultraviolet light curable liquid as droplets onto the powder layer.

In the modeling method according to the present embodiment, first, a powder layer is formed by spreading powder to a substantially uniform thickness (powder layer forming step). Next, cross-sectional data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections is generated based on the shape data of the three-dimensional object (cross-section data generation step). Next, by discharging droplets from the curable liquid discharge head provided with a discharge nozzle for discharging droplets of ultraviolet light curable liquid according to the cross-sectional data toward the powder layer, A three-dimensional object is formed by forming a combined cross-section member (cross-section member stacking step).

Here, the cross-section member stacking step will be described in detail. As shown in FIG. 9A, an ultraviolet light curable liquid that is cured by irradiation with ultraviolet light is discharged as droplets from the curable liquid discharge head 61 of the head unit 60 toward the powder layer. Since the head unit 60 includes a plurality of curable liquid discharge heads 61, it can be applied over a wide area of the powder layer at the same time by a single droplet discharge operation. Then, the liquid droplets discharged from the curable liquid discharge head 61 are sucked into the gap between the powders by a capillary phenomenon, spread in a substantially hemispherical shape, and touch the polymerization initiator applied to the powder surface. Initiate polymerization. FIG. 9A shows a state in which small droplets are discharged in this way and penetrate into the powder layer.

Next, control of the curing rate of the ultraviolet light curable liquid attached to the powder layer will be described. FIG. 9 (b)
(C) has shown a mode that a cross-section member is formed, controlling the cure rate of an ultraviolet light hardening liquid. In the present embodiment, the curing rate of the ultraviolet curable liquid is controlled by using the ultraviolet light irradiation unit 50 as a curing rate control means for controlling the curing rate of the ultraviolet curable liquid and the suppressing member 70 that suppresses the transmission of ultraviolet light. ing.

Specifically, as shown in FIG. 9B, the suppressing member 70 is disposed between the ultraviolet light irradiation unit 50 and the powder layer coated with the ultraviolet light curable liquid. The restraining member 70 is provided with an opening / closing part having an aperture mechanism at an arbitrary position. In this embodiment, an opening / closing part is provided at a location corresponding to a region where the ultraviolet light curable liquid is applied to the powder layer. First, the aperture mechanism of the opening / closing part is opened corresponding to the location where the ultraviolet light curable liquid is applied, and as shown in the figure, a relatively small opening (opening 70a
) In the first open state. In the present embodiment, the opening / closing parts corresponding to all the places where the ultraviolet light curable liquid is applied are set to be the same opening part 70a. In this state,
The ultraviolet light is irradiated from the ultraviolet light irradiation unit 50 toward the powder layer. The ultraviolet light irradiated from the ultraviolet light irradiation unit 50 passes through the opening 70a and is irradiated onto the powder layer coated with the ultraviolet light curable liquid. On the other hand, since the ultraviolet light irradiated to the region of the suppressing member 70 other than the opening 70a is suppressed by the suppressing member 70, the powder layer is not irradiated. Therefore, there are many regions that suppress the irradiated ultraviolet light, and the amount of ultraviolet light applied to the powder layer is small, so that the curing rate of the ultraviolet light curable liquid can be made relatively gradual.

Next, as shown in FIG. 9C, the aperture mechanism of the opening / closing part is further opened to be in the second open state where a relatively large opening (opening part 70b) is formed. In this state, the ultraviolet light is irradiated from the ultraviolet light irradiation unit 50 toward the powder layer. The ultraviolet light irradiated from the ultraviolet light irradiation unit 50 is the opening 7.
The powder layer to which the ultraviolet light curable liquid is applied is irradiated through 0b. Therefore, since there are few areas which suppress ultraviolet light and there are many irradiation amounts of the ultraviolet light irradiated to a powder layer, the hardening rate of an ultraviolet light hardening liquid can be made comparatively quick.

As explained above, in the first open state, since the amount of ultraviolet light irradiated to the ultraviolet light curable liquid is small, the curing speed of the ultraviolet light curable liquid is slow, and the ultraviolet light curable liquid quickly It penetrates to the bottom surface. In the second open state, since the amount of ultraviolet light irradiated to the ultraviolet light curable liquid increases, the curing speed of the ultraviolet light curable liquid increases, and the entire curing of the powder layer to which the ultraviolet light curable liquid adheres is achieved. As a result, the entire powder layer is hardened and a new cross-sectional member is formed.

Therefore, according to the second embodiment, in addition to the effects of the first embodiment, there are the following effects.

(1) When the ultraviolet light curing unit is irradiated with ultraviolet light from the ultraviolet light irradiation unit 50 to cure the ultraviolet light curing solution, the powder layer and the ultraviolet light irradiation unit 50 The suppression member 70 was arrange | positioned between these. And the irradiation amount of the ultraviolet light with respect to a powder layer was controlled by changing the opening-and-closing state of the opening-and-closing part of the suppression member 70. FIG. Therefore, the curing rate of the ultraviolet light curable liquid adhering to the powder layer can be controlled according to the open / closed state of the open / close portion of the suppressing member 70.

(2) For example, even when the type and properties of the ultraviolet light curable liquid to be discharged are different, the curing rate of the ultraviolet light curable liquid can be easily controlled by controlling the ultraviolet light irradiation amount, and the conditions are determined. The workability can be improved.

C. Variations:
The present invention is not limited to the above-described embodiment, and some modifications can be considered. Hereinafter, these modified examples will be briefly described.

C-1. First modification:
In the first embodiment, liquid droplets are ejected when the curable liquid ejection head 32 moves forward and backward, but of course, liquid droplets may be ejected only during forward movement. In order to eject droplets at the time of reverse movement and land the liquid droplets at an accurate position, advanced processing is required. On the other hand, if liquid droplets are discharged at the time of backward movement, the liquid droplets can be discharged in a short time. As a result, it becomes possible to quickly model a three-dimensional object.

C-2. Second modification:
In the first embodiment, the description has been made on the assumption that the permeation speed control means ejects droplets in two steps. However, the discharge may be performed in a larger number of times instead of twice. However, the more times the curable liquid droplets are ejected separately, the more time it takes to move the curable liquid ejection head 32 back and forth over and over again. Therefore, it is desirable to discharge in two or three times.

C-3. Third modification:
In the first embodiment, it has been described that there is no significant difference in droplet size between a droplet discharged first and a droplet discharged later. However, by changing the size of the droplets, the droplets ejected first may be small droplets, and the droplets ejected later may be large droplets. As described above, since the droplets ejected first try to spread not only in the depth direction but also in the lateral direction, in order to suppress the unevenness formed on the surface, the smaller the droplet ejected earlier, desirable. In addition, since the liquid droplets discharged later are prevented from spreading in the horizontal direction by the liquid droplets discharged first, and soak in the depth direction preferentially, the lower surface side of the portion where the liquid droplets were previously discharged is also included. In order to spread the entire powder layer and bond the formed cross-sectional member on the previously formed cross-sectional member and laminate them,
It is desirable to eject larger droplets.

C-4. Fourth modification:
In the first embodiment, the curable liquid ejection head 3 extends in a direction that intersects the direction in which the powder layer is formed.
The cross-sectional member may be formed by discharging a droplet of the curable liquid while reciprocating 2. In this way, the cross-section member can be formed by discharging the droplets by reciprocating the curable liquid discharge head 32 immediately after the end where the powder layer is formed. Therefore, even when the droplets must be ejected from the curable liquid ejection head 32 in a plurality of times in order to form the cross-sectional member, the cross-sectional member can be efficiently formed in a short time, and the tertiary It becomes possible to quickly model the original object.

C-5. Fifth modification:
In the first embodiment, the curable liquid ejection head 32 that reciprocates on the powder layer is used. However, the present invention is not limited to this. For example, a head unit configured by aligning a plurality of heads may be used ( For example, see FIG. Even in this case, a plurality of droplets can be ejected in a plurality of times, and the later ejected droplets can be ejected between the previously ejected droplets.

C-6. Sixth modification:
In the first embodiment, the curable liquid is discharged to every other position, and the liquid droplets discharged afterwards have a smooth surface by creating a state in which both sides are sandwiched by the liquid droplets previously discharged. Although the modeling part was formed, it is not limited to this. For example, a suppressing member that suppresses transmission of ultraviolet light may be used. Specifically, as shown in FIG. 10, droplets of the curable liquid are ejected from the head unit 60 toward the powder layer, and the droplets are attached to the powder layer (FIG. 10A). And FIG. 10 (b
), The suppressing member 80 is disposed between the head unit 60 and the powder layer. And the opening part 80a is formed in the position of the suppression member 80 corresponding to every other position where the droplet was apply | coated. In this state, ultraviolet light is irradiated from the ultraviolet light irradiation unit 50. The irradiated ultraviolet light is irradiated to the powder layer to which the curable liquid is attached through the opening 80a. On the other hand, ultraviolet light is not transmitted in the region of the suppressing member 80 other than the opening 80a. Accordingly, the portion of the powder layer to which the curable liquid corresponding to the opening 80a is attached is cured in advance. Next, as shown in FIG. 10C, an opening 80b is formed at a position corresponding to a position other than the portion where the curable liquid has been cured first, and ultraviolet light is irradiated.
Even in this case, the curable liquid to be irradiated with ultraviolet light later is disturbed by the previously irradiated cured portion, so that it cannot spread so much in the lateral direction, and as a result, it is preferential in the depth direction. Soak up. Eventually, the curable liquid irradiated with ultraviolet light first spreads in the horizontal direction as well as the depth direction, but the curable liquid irradiated later is suppressed in the depth direction because the lateral spread is suppressed. As a whole, the curable liquid can be preferentially infiltrated in the depth direction. As a result, the unevenness formed on the surface of the three-dimensional object can be suppressed, and a three-dimensional object having a smooth surface can be formed. Furthermore, if the suppressing member 80 is disposed at an arbitrary position, the curing rate of the curable liquid can be controlled.

C-7. Seventh modification:
In the second embodiment, the ultraviolet light curable liquid is cured by irradiating ultraviolet light as an example of electromagnetic waves.
It is not limited to this. For example, you may use the hardening | curing liquid which hardens | cures by each irradiation using infrared rays, visible light, X-ray | X_line etc. other than that. Even if it does in this way, a molded article can be formed.

C-8. Eighth modification:
In the second embodiment, the suppressing member that suppresses the transmission of ultraviolet light is used, but a filter having a different transmittance depending on the wavelength of the ultraviolet light may be used. Even in this case, since the irradiation amount of the ultraviolet light transmitted is controlled by the transmittance of the ultraviolet light, the curing rate of the ultraviolet light curable liquid can be controlled.

C-9. Ninth modification:
In the second embodiment, the ultraviolet light irradiation unit 50 is used as the curing rate control means, but the present invention is not limited to this. For example, the structure which employ | adopts the thermosetting liquid hardened | cured by heating and heats using the heating part with respect to the said thermosetting liquid may be sufficient. Even in this case, the curing rate of the curable liquid can be controlled by adjusting the heating.

C-10. Tenth modification:
In the above embodiment, the ultraviolet light curable liquid having the same curing speed is ejected as droplets. However, the present invention is not limited to this, and a plurality of types of curable liquids having different curing speeds may be ejected as droplets. For example, the curable liquid discharged later may discharge the curable liquid having a slower curing speed than the previously discharged curable liquid as droplets. In this way, the curable liquid discharged first and the curable liquid discharged later are cured at the same time, so that the curing rate can be controlled, and further, variation in the curing rate in the powder layer can be suppressed. it can.

C-11. Eleventh modification:
In 2nd Embodiment, although the aperture mechanism was employ | adopted for the control member, it is not limited to this. For example, it is good also as a structure which provides a moving means in a suppression member and interrupts | blocks the ultraviolet light from an ultraviolet light irradiation part arbitrarily. Even in this case, the irradiation amount of ultraviolet light can be adjusted.

C-12. Twelfth modification:
In the second embodiment, the ultraviolet light irradiation unit 50 is fixed and arranged, but the present invention is not limited to this. You may provide the moving means to which the ultraviolet light irradiation part 50 moves. In this case, it moves to an arbitrary part of the powder layer to which the ultraviolet light curable liquid is applied and is irradiated with ultraviolet light. Even in this way, the curing rate of the ultraviolet light curable liquid at the selected location can be controlled.

C-13. Thirteenth modification:
In the second embodiment, as a curing rate control means for controlling the curing rate of the ultraviolet light curing liquid,
Although the ultraviolet light irradiation part 50 and the suppression member 70 were used, it is not limited to this, The suppression member 70 may be abbreviate | omitted. In this case, the output of the ultraviolet light emitted from the ultraviolet light irradiation unit 50 may be controlled by the control unit 44 of the arithmetic processing unit 40. Even in this way, by controlling the irradiation amount of ultraviolet light,
The curing rate of the ultraviolet light curable liquid can be controlled.

The three-dimensional modeling apparatuses 100 and 110 of the present embodiment have been described above. However, the present invention is not limited to all the examples described above, and can be implemented in various modes without departing from the spirit of the present invention. is there. Of course, you may employ | adopt the structure which combined the structure of said each embodiment.

For example, in the above-described embodiment, a case has been described in which a curable liquid that starts polymerization by ultraviolet light is used as the curable liquid for forming the surface region. However, a curing liquid (for example, instant adhesive) that starts polymerization immediately when it comes into contact with moisture (or oxygen, etc.) in the air.
It is good also as using.

Explanatory drawing which showed the rough structure of the three-dimensional modeling apparatus in 1st Embodiment. The perspective view which showed the positional relationship in which the powder layer formation part, the hardening liquid discharge head, and the ultraviolet light irradiation part are mounted in the three-dimensional modeling apparatus in 1st Embodiment. Explanatory drawing which showed notionally how a 3D object was modeled with a 3D modeling apparatus. Explanatory drawing which showed notionally how a three-dimensional object was modeled by discharging a droplet on a powder layer by a general method. Explanatory drawing which showed notionally that a three-dimensional modeling apparatus in 1st Embodiment modeled a three-dimensional object by discharging a droplet on a powder layer. Explanatory drawing which showed the rough structure of the three-dimensional modeling apparatus in 2nd Embodiment. The perspective view which showed the positional relationship in which the powder layer formation part, the head unit, the ultraviolet light irradiation part, and the suppression member are mounted in the three-dimensional modeling apparatus in 2nd Embodiment. The top view of the head unit in a 2nd embodiment. Explanatory drawing which showed notionally that a three-dimensional modeling apparatus in 2nd Embodiment modeled a three-dimensional object by discharging a droplet on a powder layer. Explanatory drawing which showed notably the mode that the three-dimensional modeling apparatus in a modification forms a three-dimensional object by discharging a droplet on a powder layer.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Modeling part, 12 ... Frame, 14 ... Bottom face part, 16 ... Bottom face drive part, 20 ... Powder layer formation part,
22 ... Hopper, 24 ... Powder supply roller, 26 ... Extension roller, 30 ... Curing liquid supply unit, 32
61 ... Curing liquid discharge head, 32n ... Discharge nozzle, 34 ... Curing liquid storage unit, 40 ... Calculation processing unit, 42 ... Cross-section data generation unit, 44 ... Control unit, 50 ... Ultraviolet light irradiation unit, 60 ... Head unit, 70, 80 ... suppression member, 100, 110 ... three-dimensional modeling apparatus.

Claims (21)

A three-dimensional modeling apparatus for modeling a three-dimensional object by bonding powders together with a curing liquid,
A powder layer forming means for forming a powder layer by spreading the powder to a substantially uniform thickness;
A discharge nozzle for discharging droplets of the curable liquid, a curable liquid discharge head for discharging droplets of the curable liquid toward the powder layer while reciprocating on the powder layer;
Cross-sectional data generating means for generating cross-sectional data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross-sections based on the shape data of the three-dimensional object;
By discharging droplets of the curable liquid toward the powder layer according to the cross-sectional data, the cross-sectional member in which the powders of the powder layer are combined is formed, and the cross-sectional member is formed in a lower layer. Cross-sectional member laminating means for laminating on the cross-sectional member that is,
The cross member stack means comprises a penetration speed control means for controlling the speed soak to the powder layer of the cured fluid discharged,
With
The cross-sectional member stacking means discharges the plurality of droplets discharged onto the passage path of the discharge head in a plurality of times when discharging the droplets of the curable liquid, and the droplets discharged later are A three-dimensional modeling apparatus which is means for forming the cross-sectional member by discharging between previously discharged liquid droplets. The three-dimensional modeling apparatus according to claim 1 ,
The cross-section member stacking means discharges droplets to every other position along the moving direction of the curable liquid discharge head when discharging the curable liquid droplets while reciprocating the curable liquid discharge head. And the three-dimensional modeling apparatus which is a means to form the said cross-sectional member. The three-dimensional modeling apparatus according to claim 1 or 2 ,
The cross-sectional member stacking unit is a three-dimensional modeling apparatus that is a unit that forms the cross-sectional member by discharging droplets of the curable liquid when the curable liquid discharge head moves forward and backward. A three-dimensional modeling apparatus according to any one of claims 1 to 3,
The cross-sectional member stacking means forms the cross-sectional member by discharging the curable liquid droplets while reciprocating the curable liquid discharge head in a direction crossing the direction of forming the powder layer. A three-dimensional modeling apparatus as a means. In the three-dimensional modeling apparatus according to any one of claims 1 to 4,
The three-dimensional modeling apparatus, wherein the cross-sectional member stacking unit discharges a droplet having a larger size than that of the previously ejected droplet. In the three-dimensional modeling apparatus as described in any one of Claims 1-5 ,
The three-dimensional modeling apparatus characterized in that the cross-sectional member laminating unit includes a curing rate control unit that controls a curing rate of the curable liquid discharged to the powder layer. The three-dimensional modeling apparatus according to claim 6 ,
The curable liquid is an electromagnetic wave curable liquid that is cured by irradiation with electromagnetic waves,
The three-dimensional modeling apparatus, wherein the curing speed control means includes an electromagnetic wave irradiation unit that irradiates an electromagnetic wave to the powder layer to which the electromagnetic wave curable liquid is attached. The three-dimensional modeling apparatus according to claim 7 ,
The three-dimensional modeling apparatus, wherein the curing speed control means further includes a suppressing member that suppresses transmission of the electromagnetic wave between the electromagnetic wave irradiation unit and the powder layer. The three-dimensional modeling apparatus according to claim 7 or 8 ,
The curable liquid is an ultraviolet light curable liquid that is cured by irradiation with ultraviolet light,
The curing speed control means includes an ultraviolet light irradiation unit that irradiates the powder layer to which the ultraviolet light curable liquid is adhered with ultraviolet light, and further, between the ultraviolet light irradiation unit and the powder layer. And a suppressing member for suppressing the transmission of the ultraviolet light. The three-dimensional modeling apparatus according to claim 6 ,
The curable liquid is a thermosetting liquid that is cured by heating,
The three-dimensional modeling apparatus, wherein the curing speed control means includes a heating unit that heats the powder layer to which the thermosetting liquid is attached. The three-dimensional modeling apparatus according to claim 6 ,
The curing speed control means is the curable liquid discharged from the curable liquid discharge head,
A three-dimensional modeling apparatus characterized in that a curable liquid discharged later discharges a curable liquid having a slower curing speed than the previously discharged curable liquid as droplets. A three-dimensional modeling method for modeling a three-dimensional object by bonding powders together with a curing liquid,
A powder layer forming step of forming a powder layer by spreading the powder to a substantially uniform thickness;
A cross-sectional data generation step for generating cross-sectional data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections based on the shape data of the three-dimensional object;
While the curable liquid discharge head provided with the discharge nozzle for discharging the curable liquid droplets is reciprocated on the powder layer, the liquid droplets are discharged toward the powder layer according to the cross-sectional data. By forming a cross-sectional member in which the powders of the powder layer are combined, the cross-sectional member lamination step of laminating the cross-sectional member on the cross-sectional member formed in the lower layer,
With
In the cross-section member stacking step, the cross-section member is formed while controlling the speed of soaking into the powder layer of the discharged curable liquid,
In the cross-section member stacking step, when discharging the curable liquid droplets while reciprocating the curable liquid discharge head, a plurality of liquid droplets discharged onto the passage path of the discharge head are divided into a plurality of times. In addition, the three-dimensional modeling method is a step of forming the cross-sectional member by discharging the liquid droplets to be discharged later between the previously discharged liquid droplets. The three-dimensional modeling method according to claim 12 ,
In the cross-section member stacking step, when discharging the curable liquid droplets while reciprocating the curable liquid discharge head, the liquid droplets are discharged to every other position along the moving direction of the curable liquid discharge head. And the three-dimensional modeling method characterized by forming the said cross-sectional member. In the three-dimensional modeling method according to claim 12 or 13 ,
In the cross-sectional member stacking step, the cross-sectional member is formed by discharging droplets of the curable liquid when the curable liquid discharge head moves forward and backward. In the three-dimensional modeling method according to any one of claims 12 to 14 ,
In the cross-sectional member laminating step, the cross-sectional member is formed by discharging droplets of the curable liquid while reciprocating the curable liquid discharge head in a direction crossing the direction in which the powder layer is formed. A three-dimensional modeling method characterized by this. In the three-dimensional modeling method according to any one of claims 12 to 15 ,
In the cross-sectional member stacking step, the three-dimensional modeling method is characterized in that a droplet having a larger size than that of the previously ejected droplet is ejected. The three-dimensional modeling method according to any one of claims 12 to 16 ,
In the cross-sectional member laminating step, the cross-sectional member is formed while controlling the curing rate of the curable liquid discharged to the powder layer. The three-dimensional modeling method according to claim 17 ,
In the cross-sectional member lamination step, an electromagnetic wave curable liquid that is cured by irradiation with electromagnetic waves is discharged as droplets, and the powder layer to which the electromagnetic wave curable liquid is attached is irradiated with electromagnetic waves. . The three-dimensional modeling method according to claim 18 ,
In the cross-section member stacking step, an ultraviolet light curable liquid that is cured by irradiation with ultraviolet light is discharged as droplets, and the powder layer to which the ultraviolet light curable liquid is attached is irradiated with ultraviolet light. Three-dimensional modeling method. The three-dimensional modeling method according to claim 17 ,
In the cross-section member stacking step, a thermosetting liquid that is cured by heating is discharged as droplets, and the powder layer to which the thermosetting liquid is attached is heated. The three-dimensional modeling method according to claim 17 ,
In the cross-sectional member stacking step, the three-dimensional modeling method is characterized in that the curable liquid discharged later discharges a curable liquid having a slower curing speed than the previously discharged curable liquid as droplets.

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