JP2016198897A - Method for forming three-dimensional molded object - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide means for forming a three-dimensional molded object having good surface quality.SOLUTION: A method for forming a three-dimensional molded object 15 is provided, in which an object is formed by stacking layers comprising at least two types of inks in an ink for modeling material, a decorative ink and an ink for a support material. A gap 17 is formed at least either in at least a part of a boundary of two inks adjoining to each other in one layer or in at least a part along the boundary.SELECTED DRAWING: Figure 5

Description

  The present invention relates to a method for forming a three-dimensional structure, and more particularly, to a method for forming a three-dimensional structure by stacking layers made of a model material and a support material.

  As a technique for forming a three-dimensional structure, an inkjet method, a melt deposition method (FDM), an ink-jet binder method, a sheet lamination method, a stereolithography method (SL), and a powder sintering method (SLS) : Selective Laser Sintering).

  In particular, as an ink jet method, a method of laminating layers formed by discharging a model material that is cured by receiving light irradiation is frequently used. In this method, first, the design / mechanism or the like of the external appearance of a three-dimensional structure to be finally obtained is converted into data by three-dimensional CAD, and then, multilayer pattern data obtained by slicing the data at a predetermined interval is created. Subsequently, according to the pattern data of each layer, a model material is discharged and each layer is laminated to form a three-dimensional structure.

  In such a method, of the two upper and lower layers to be laminated, the outer peripheral edge of the upper layer is larger than the outer peripheral edge of the lower layer, that is, a part of the upper layer protrudes (overhangs). In some cases, the structure is shaped. In this case, the support material is formed adjacent to the outer peripheral edge of the lower layer, and the overhang portion of the upper layer is laminated on the support material. Note that the support material is a portion that is not configured as a three-dimensional object, and thus is removed at an appropriate timing.

  The surface of the model material and the support material immediately after discharging has irregularities. Therefore, a method of flattening the surface of the layer using a roller or the like every time one layer is formed by the model material and the support material is employed.

US Pat. No. 5,503,785

  However, when the surface of the layer formed by the model material and the support material is flattened by a roller or the like, the surface of the finally obtained three-dimensional structure becomes rough.

  This will be described with reference to FIG. FIG. 14 is a schematic diagram showing a process of flattening a layer formed of a model material and a support material with a roller in the prior art. As shown in FIG. 14, the surface of the layer formed by the model material M or the support material S advances in the traveling direction A while the roller R rotates in the rotational direction B, so that the surface of the layer is flattened. . At this time, as the roller R travels, as shown in the region P, a model material M dragged to the downstream side in the traveling direction A by the roller R is generated. When the roller R moves as it is, the dragged model material M is wound on the support material S side by the roller R, so that they are mixed at the boundary between the model material M and the support material S. The surface of the three-dimensional structure formed in this way becomes rough due to the model material M wound on the support material S side.

  The above problem can also occur at the boundary between the model material and the decorative ink. In this case, when the model material dragged by the roller is wound on the decorative ink side, the model material and the decorative ink are mixed at the boundary, and the three-dimensional structure formed in this way The surface quality of the will deteriorate.

  Patent Document 1 discloses a method of providing a gap between the support material and the model material so as to prevent mixing of the support material and the model material, and putting a liquid into the gap. However, in the above method, in the ink jet printer, a new head for ejecting liquid is required in addition to the head for ejecting ink.

  Then, this invention is made | formed in view of said problem, The objective is providing the formation method of the three-dimensional structure which can form the three-dimensional structure of favorable surface quality. It is in.

  The method for forming a three-dimensional structure according to one aspect of the present invention is a tertiary method in which layers made of at least two types of ink among model material ink, decoration ink, and support material ink are stacked and formed. A forming method of an original model, wherein a planarizing member is formed on a surface of the one layer formed in the forming step by ejecting the at least two kinds of inks and forming the one layer. A flattening step of flattening the surface of the one layer by moving in the first direction while leveling the ink on the surface. In the forming step, two adjacent layers in the one layer are included. At least a part of the boundary of the kind of ink and at least a part of the boundary along the boundary contain extra ink generated when the ink is leveled in the planarization step. And forming a clearance for.

  According to the above method, since the ink dragged during the flattening enters the gap, the dragged ink can be prevented from mixing at the boundary between the ink and the adjacent ink. For this reason, it is possible to prevent the surface quality of the three-dimensional structure from being deteriorated by mixing two types of adjacent inks at the boundary between them. Thus, a three-dimensional structure with good surface quality can be obtained by the method for forming a three-dimensional structure according to one embodiment of the present invention.

  In the method for forming a three-dimensional structure according to one aspect of the present invention, in the forming step, at least one of the model material ink and the decorating ink and the support material ink are ejected. In the one layer, at least one of the model material ink and the decoration ink is located at a location located upstream of the support material ink in the first direction. The gap is formed in at least part of the boundary of the ink and at least one part of the ink located upstream of the support material ink in the first direction along the boundary.

  According to the above method, in the process of flattening by the flattening member, the ink dragged by the flattening member to the downstream side in the traveling direction of the flattening member enters the gap, and the dragged ink is supported by the support material. It is possible to prevent the ink from being caught on the ink side, and to form a three-dimensional structure having a smooth surface.

  In the method for forming a three-dimensional structure according to one aspect of the present invention, in the forming step, at least one of the model material ink and the decorating ink and the support material ink are ejected. In the one layer, both of the support material inks are located on the upstream side in the first direction with respect to at least one of the model material ink and the decoration ink. The gap is formed in at least a part of the boundary of the support material and / or at least a part of the support material ink along the boundary.

  According to the above method, in the process of flattening by the roller, the support material ink dragged by the roller to the downstream side in the moving direction of the roller enters the gap, and the dragged support material ink is the support material. It is possible to prevent the material ink from being caught on the ink side adjacent to the material ink, and to form a three-dimensional structure having a smooth surface.

  According to one aspect of the present invention, in the formation process, the three-dimensional structure forming method may include the entire boundary between the two adjacent inks in the one layer, or the entire portion along the boundary. The gap is formed.

  According to the above method, it is possible to prevent the surface quality of the three-dimensional structure from being deteriorated by mixing the two at the entire boundary between the two types of adjacent inks, and a tertiary having a good surface quality. An original model can be formed.

  In the method of forming a three-dimensional structure according to one aspect of the present invention, in the forming step, the one layer is formed by discharging the model material ink, the decorating ink, and the support material ink. In the one layer, the decorative ink is downstream of the model material ink in the first direction and upstream of the support material ink in the first direction. The gap is formed in at least a part of the boundary between the decorative ink and the support material ink at a position located at the position.

  According to the above method, by forming a gap at the boundary between the decorative ink and the support material ink, the model material ink or the decorative ink dragged during the planarization enters the gap, It is possible to prevent the dragged ink for the model material or the decoration ink and the support material ink from being mixed at the boundary. Therefore, the surface of the obtained three-dimensional structure becomes smooth, and a three-dimensional structure with good surface quality is obtained.

In the method for forming a three-dimensional structure according to one aspect of the present invention, in the forming step,
The model material ink, at least one kind of the decoration ink, and the support material ink are ejected to form the one layer. In the one layer, at least one kind of the decoration material is used. The boundary between the adjacent model material ink and the decorative ink at the location where the ink is located downstream of the model material ink in the first direction, or two adjacent types of the decorative ink. The gap is formed in at least a part of the boundary.

  According to the above method, since the gap is formed at the boundary between the adjacent model material ink and the decorative ink, or the boundary between the two adjacent types of decorative ink, the surface layer side (outer periphery) Decorative ink is formed on the side). Therefore, the decorative ink formed on the surface layer side (outer periphery side) than the gap forms the outermost layer (outermost periphery) of the three-dimensional structure. Therefore, the edge of the outermost layer (outermost circumference) of the three-dimensional structure can be a square edge with a small radius of curvature, and a three-dimensional structure with better surface quality can be obtained.

  In the method for forming a three-dimensional structure according to one aspect of the present invention, in the forming step, at least one of the model material ink and the decorating ink and the support material ink are ejected. The gap is formed in at least a part of the boundary between the ink for the support material in the one layer and the ink adjacent to the support material ink in the one layer, and is formed in the formation step. By adjusting the width of the gap, the glossiness of the surface of the three-dimensional structure is adjusted.

  According to the above method, the gloss of the surface of the finally obtained three-dimensional structure can be obtained by changing the width of the gap formed at the boundary between the ink for the support material in each layer and the ink adjacent to the ink for the support material. The degree can be adjusted.

  According to one embodiment of the present invention, a three-dimensional structure with good surface quality can be formed.

(A) in a figure is a perspective view of the three-dimensional structure formed in one Embodiment of this invention, (b) in a figure is arrow sectional drawing of (a) in a figure. It is a figure which shows the main structures of the formation apparatus of the three-dimensional structure in one Embodiment of this invention. FIG. 2 is a diagram illustrating a specific configuration of a recording unit according to an embodiment of the present invention, and is a diagram illustrating an ink ejection surface (lower surface) of the recording unit. It is a flowchart which shows the flow of the formation method of the three-dimensional structure based on one Embodiment of this invention. (A)-(c) in a figure is a figure which shows each process of the formation method of the three-dimensional structure based on one Embodiment of this invention. (A) and (b) in a figure is a top view of the layer of the three-dimensional modeling material and support material before planarization, and is a figure which shows the example of the shape of the clearance gap provided in the boundary of a three-dimensional modeling material and a support material is there. In (a) of FIG. 5, it is the figure which specified the ink for modeling and the ink for decorating which are contained in a three-dimensional modeling material. It is a figure which shows the process in which the recording unit which concerns on one Embodiment of this invention forms one layer with a three-dimensional modeling material and a support material. (A) and (b) in the figure is a top view of the layer of the three-dimensional modeling material and the support material before flattening, along the boundary between the three-dimensional modeling material and the support material provided in the three-dimensional modeling material FIG. (A) in the figure is a diagram in which the modeling ink and the decoration ink included in the three-dimensional modeling material are clearly shown in (a) of FIG. 9, and (b) in the figure is ( In (a), it is the figure which formed multiple clearance gaps along the boundary of a three-dimensional modeling material and a support material in the three-dimensional modeling material of one layer. (A) And (b) in a figure is a figure which shows the example of the position of a clearance gap in the case of providing a clearance gap in the location where a support material is located in the upstream of the advancing direction of a roller rather than a three-dimensional modeling material. (A) in a figure is an external view of a three-dimensional structure, (b) in a figure is a figure which shows the arrow cross section in the cutting line AA 'of (a) of FIG. (A) And (b) in a figure is a figure which shows the example of the position of the clearance gap provided when forming the three-dimensional structure of a hollow structure. It is the schematic diagram which showed the process in which the layer formed with the three-dimensional modeling material and support material in a prior art is planarized with a roller.

[First Embodiment]
Hereinafter, a method for forming a three-dimensional structure according to an embodiment of the present invention will be described. First, a three-dimensional structure formed in the present embodiment and a forming apparatus for forming the three-dimensional structure are described. An outline will be described.

(3D objects)
FIG. 1 is a diagram illustrating a three-dimensional structure formed in the present embodiment. FIG. 1A is an external view of a three-dimensional structure, and FIG. 1B is a diagram showing a cross-section taken along line AA ′ in FIG.

  The three-dimensional structure 5 shown in FIG. 1A has a quadrangular prism shape, and the four side surfaces except the upper surface and the lower surface have a trapezoid whose lower side is shorter than the upper side. The shape of the three-dimensional structure 5 is not limited to the shape shown in FIG. 1, and may be any shape such as a cylinder, a spherical shape, a hollow structure, a ring structure, or a horseshoe shape.

  The three-dimensional structure 5 has a modeling main body part and a decoration part. The modeling body part is composed of the modeling layer 1 and the light reflection layer 2, and the decoration part is composed of the color layer 3 and the transparent layer 4. As shown in FIG. 1B, the modeling layer 1, the light reflection layer 2, the color layer 3, and the transparent layer 4 are formed from the inner side (center side) of the three-dimensional modeled object 5 toward the surface layer side (outer peripheral side). They are formed in this order.

  In this embodiment, the modeling layer 1 and the light reflection layer 2 are regarded as “modeling main body part”, and the surface of the modeling main body part is covered with the “decorative part” having the color layer 3 and the transparent layer 4. However, the present invention is not necessarily limited to this. For example, only the modeling layer 1 may be regarded as a modeling body part, or only the color layer 3 may be regarded as a decoration part. Alternatively, the modeling body part may be configured only by the modeling layer 1 without providing the light reflecting layer 2, or the modeling body part may be configured only by the light reflecting layer 2 without providing the modeling layer 1. It is not necessary to provide the decoration part. Moreover, the cavity may be provided in the modeling main body part.

  The modeling layer 1, the light reflection layer 2, the color layer 3, and the transparent layer 4 are all deposited by ejecting ink by an ink jet method using the forming apparatus 50 (FIG. 2) of this embodiment described later. Is formed by.

  As the ink, an ultraviolet curable ink can be used. If ultraviolet curable ink is used, since it can be cured in a short time, it is easy to stack, and there is an advantage that the three-dimensional structure 5 can be manufactured in a shorter time. The ultraviolet curable ink contains an ultraviolet curable compound. The ultraviolet curable compound is not limited as long as it is a compound that cures when irradiated with ultraviolet rays. Examples of the ultraviolet curable compound include a curable monomer and a curable oligomer that are polymerized by irradiation with ultraviolet rays. Examples of the curable monomer include low-viscosity acrylic monomers, vinyl ethers, oxetane monomers, and cycloaliphatic epoxy monomers. Examples of the curable oligomer include acrylic oligomers.

  The present invention is not limited to the ultraviolet curable ink, and for example, a thermoplastic ink can be used. If thermoplastic ink is used, the discharged heated ink is cured by cooling to room temperature. At this time, a method of forcibly cooling in order to cure in a shorter time may be used.

(Each layer of 3D objects)
The modeling layer 1 is a layer formed by the central structure of the modeling main body portion, and is formed of a model material. The light reflection layer 2 is a layer formed of light-reflective ink, and is a light reflection that can reflect light in the entire visible light region at least on the surface of the light reflection layer 2 on the color layer 3 side. It has sex. Specifically, the light reflection layer 2 can be formed from an ink containing a metal powder or an ink containing a white pigment, but is preferably formed from a white ink. By forming from a white ink, the light which entered from the surface layer side of the three-dimensional structure 5 in the light reflection layer 2 can be favorably reflected, and coloring by subtractive color mixture can be realized.

  The color layer 3 is formed by ink containing a colorant. The decorative ink containing a colorant (hereinafter sometimes referred to as decorative ink) includes yellow (Y), magenta (M), cyan (C), and black (K), and light-colored inks. However, the present invention is not limited to this, and red (R), green (G), blue (B), orange (Or), or the like may be added. It is also possible to use metallic, pearl or phosphor colors. In order to express a desired color tone, one or more kinds of these decorative inks are used.

  Finally, the transparent layer 4 is formed from a transparent ink. The transparent ink may be any ink that can form a transparent layer having a light transmittance of 50% or more per unit thickness. The unit thickness is the minimum thickness of the transparent layer. If the light transmittance per unit thickness of the transparent layer is less than 50%, the light transmission is undesirably blocked, and the molded article cannot exhibit a desired color tone due to subtractive color mixing, which is not desirable. Preferably, an ink having a light transmittance of 80% or more per unit thickness of the transparent layer is used, and an ink having a light transmittance of 90% or more per unit thickness of the transparent layer is more preferably used. .

  The transparent layer 4 not only has a function as a protective layer of the color layer 3 but also has an advantage of enabling the three-dimensional structure 5 to be densely manufactured in the present embodiment employing the lamination method. There is an effect. That is, if the color layer 3 constitutes the outermost layer of the three-dimensional structure 5, the color layer 3 may not be formed with high accuracy. However, since the transparent layer 4 is formed on the outermost layer of the three-dimensional structure 5 as in the present embodiment, the color layer 3 is formed with high accuracy, so that the transparent layer 4 exhibits a desired color tone. Can contribute.

  In addition, if the color layer 3 constitutes the outermost layer of the three-dimensional structure 5, the color layer 3 is exposed, so that discoloration due to rubbing or fading due to ultraviolet rays is likely to occur. However, since the transparent layer 4 is formed on the outermost layer of the three-dimensional structure 5 as in the present embodiment, decolorization or fading can be prevented.

(Forming equipment)
FIG. 2 is a diagram illustrating a main configuration of a three-dimensional structure forming apparatus 50 (hereinafter, referred to as a forming apparatus 50) in the present embodiment. FIG. 2 also shows a three-dimensional structure 5 being formed.

  The forming apparatus 50 of the present embodiment uses a three-dimensional structure 5 including a modeling main body part and a decoration part decorating the surface of the three-dimensional structure 5 as a stacked structure shown in FIG. It is an apparatus to form. As shown in FIG. 2, the forming apparatus 50 of this embodiment includes a recording unit 10, a flattening unit 20, a control unit 30, and a base 40.

<Recording unit>
The recording unit 10 is a unit for ejecting the ink described above using an ink jet method and curing the ejected ink. FIG. 3 illustrates a specific configuration of the recording unit 10 and illustrates an ink ejection surface (lower surface) of the recording unit 10. As shown in FIG. 3, the recording unit 10 includes a carriage 23, an inkjet head 21, and a UV irradiation unit 22.

[carriage]
The carriage 23 can reciprocate along the Y axis, and has the inkjet head 21 and the UV irradiation unit 22 mounted thereon. The movement of the carriage 23 is controlled by a control unit 30 described later.

[Inkjet head]
The inkjet head 21 ejects the ink described above using an inkjet method. Specifically, in order to eject different inks, the inkjet head 21 has a first inkjet head nozzle portion 21A, a second inkjet head nozzle portion 21B, and a third inkjet head nozzle portion 21C as shown in FIG. have.

  21 A of 1st inkjet head nozzle parts are the modeling main body parts (the modeling layer 1 and the light reflection layer 2 which were shown to (b) of FIG. 1) which are some 3D modeling objects 5 shown to (b) of FIG. The ink for forming for forming is ejected. In this embodiment, a model material 11 for forming the modeling layer 1 and a white ink 12 for forming the light reflection layer 2 are used as the model material ink. For this reason, the first inkjet head nozzle portion 21 </ b> A includes a model material nozzle row MD for discharging the model material 11 and a white ink nozzle row W for discharging the white ink 12. Conventionally known model materials can be used as the model material 11, but white ink 12 ejected from the white ink nozzle row W or transparent ink 14 ejected from the transparent ink nozzle row CL described later may be used. Is possible.

  The 2nd inkjet head nozzle part 21B is a decoration part (the color layer 3 and the transparent layer 4 which were shown to (b) of FIG. 1) which is a part of the three-dimensional structure 5 shown to (b) of FIG. The decorative ink for forming is discharged. In the present embodiment, as the decorative ink, a decorative ink 13 (yellow ink, magenta ink, cyan ink, and black ink) for forming the color layer 3 and a transparent ink 14 for forming the transparent layer 4 are used. Is used. Therefore, the second ink jet head nozzle section 21B includes a yellow ink nozzle row Y for discharging yellow ink, a magenta ink nozzle row M for discharging magenta ink, and a cyan ink nozzle row C for discharging cyan ink. , A black ink nozzle row K for discharging black ink and a transparent ink nozzle row CL for discharging transparent ink are provided.

  The third inkjet head nozzle portion 21C ejects support material ink for forming a support that is not configured in the three-dimensional structure. In the present embodiment, the support material 16 is ejected as the support material ink. Therefore, a support material nozzle row S that discharges the support material 16 is provided in the third inkjet head nozzle portion 21C. Conventionally known materials such as a water-soluble ultraviolet curable resin can be used as the support material.

  A plurality of nozzle rows provided in the first inkjet head nozzle portion 21A, a plurality of nozzle rows provided in the second inkjet head nozzle portion 21B, and a nozzle example provided in the third inkjet head nozzle portion 21C are: The recording units 10 are arranged along the scanning direction (Y-axis direction). That is, as shown in FIG. 3, a yellow ink nozzle row Y, a magenta ink nozzle row M, a cyan ink nozzle row C, a black ink nozzle row K, a transparent ink nozzle row CL, and a white ink The ink nozzle row W, the model material nozzle row MD, and the support material nozzle row S are arranged in this order along the Y-axis direction.

  Each nozzle row has a plurality of nozzle holes arranged in the X-axis direction as shown in FIG. Ink may be ejected from only some of the plurality of nozzle holes. Further, the arrangement order and number of the nozzle rows are not limited to those shown in FIG.

  In the present embodiment, ink for forming the three-dimensional structure 5 (that is, ink for model material and ink for decoration) is regarded as the three-dimensional structure material 15. Therefore, in the present embodiment, the three-dimensional structure 5 is formed by laminating a layer composed of the three-dimensional structure 15 serving as the three-dimensional structure 5 and the support material 16 serving as a support that supports the three-dimensional structure 15. Form. The decorative ink is ejected downstream of the model material 11 in the traveling direction of the roll R and upstream of the support material 16.

  Here, as shown in FIG. 2, the support material 16 is not configured on the three-dimensional structure 5, but supports or holds the three-dimensional structure 15 in the formation process of the three-dimensional structure 5. Is to do. If an example of support is given, the three-dimensional structure 5 shown in FIG. 1 has a shape in which the diameter of the layers gradually expands in the stacking direction. That is, of the two upper and lower layers to be laminated, the outer peripheral end portion of the upper layer has a structure (overhang) protruding from the outer peripheral end portion of the lower layer. In this case, the support material 16 is formed adjacent to the outer peripheral edge of the lower layer of the three-dimensional modeling material 15, and the overhang portion of the upper layer is formed of the three-dimensional modeling material 15 on the support material 16. In addition, since the support material 16 is a part which is not comprised in the three-dimensional structure 5, it is removed at an appropriate timing.

  The formation method using the support material 16 can be used not only when the overhang portion is formed but also when the arch-shaped three-dimensional structure 5 is formed. In addition, the support material 16 has a damming function as another function for damming the ink so that the ink does not undesirably spread further outward when the ink at the outer peripheral edge of each layer is deposited. Therefore, also when forming the three-dimensional structure 5 having no overhang portion, a support material may be formed on the outer periphery of each layer when the layers are stacked.

[UV irradiation part]
The UV irradiation unit 22 includes a plurality of irradiators 22 </ b> A each having a light source for ink curing, and these are mounted on the carriage 23. Specifically, the UV irradiation unit 22 includes three irradiators 22A arranged along the Y-axis direction. The UV irradiation unit 22 may be provided independently as a UV irradiation unit, and is not limited to the one attached to the recording unit 10.

<Flatening unit>
The flattening unit 20 is a unit that flattens the surface of the layer formed by the ink ejected from the recording unit 10. The flattening unit 20 flattens the unevenness of the surfaces of the three-dimensional modeling material 15 and the support material 16 immediately after being discharged from the recording unit 10 by using a flattening member. In this figure, a roller R is used as a flattening member, and each time the three-dimensional modeling material 15 and the support material 16 are discharged from the inkjet head 21 to form a single layer, the roller R rotates and the inkjet head 21 is rotated. Is moved in the Y-axis direction (first direction) on the layer of the three-dimensional modeling material 15 and the support material 16 ejected from. Thereby, the surface of the layer is pressurized, and the thickness of the layer is made uniform while leveling the three-dimensional modeling material 15 and the support material 16.

  Although the specific form of the roller R is not particularly limited, it is more preferable that the outer peripheral surface is made of a material having no affinity for ink. For example, a metal roller surface with a fluorine coating such as PTFE (polytetrafluoroethylene) or a fluorine or silicon rubber attached thereto is preferable.

  A flattening member other than the roller R may be used. For example, a blade can be used as the flattening member. In this case, the three-dimensional modeling material is moved while moving the blade having the main surface perpendicular to the Y-axis direction on the layer of the three-dimensional modeling material 15 and the support material 16 ejected from the inkjet head 21 in the Y-axis direction. 15 and the support material 16 are made uniform so that the layer thickness is uniform.

<Control unit>
The control unit 30 is a unit that controls various members such as ink ejection control by the inkjet head 21, UV irradiation control by the UV irradiation unit 22, movement (scanning) control of the carriage 23, and control of the flattening unit 20. is there. In the present embodiment, when controlling the ink ejection by the inkjet head 21, the modeling data of the three-dimensional structure 5 is corrected according to the presence or absence of the overhang portion of the three-dimensional structure 5. This process is performed by the modeling data reception unit 31, the modeling data correction unit 32, and the print control unit 33 included in the control unit 30.

  The modeling data reception unit 31 acquires modeling data (including input data for forming a decorated portion) of the three-dimensional model 5. The modeling data of the three-dimensional structure 5 is a multilayer type in which the design and mechanism of the internal appearance of the three-dimensional structure 5 to be finally obtained is converted into data by three-dimensional CAD, and then the data is sliced at regular intervals. Pattern data. The pattern data of each layer indicates the discharge pattern of the three-dimensional structure 15, and when the three-dimensional structure 5 has an overhang portion, the pattern data includes the discharge pattern of the support material 16. ing. The shape data of the three-dimensional structure 5 may be acquired from the outside of the modeling data receiving unit 31, or may be stored in advance in the modeling data receiving unit 31, Or the modeling data reception part 31 may produce | generate based on the information acquired from the exterior of the modeling data reception part 31. FIG.

  The modeling data correction unit 32 generates corrected modeling data in which the modeling data is corrected according to the presence or absence of the overhang portion of the three-dimensional model 5. Specifically, when the three-dimensional structure 5 does not have an overhang portion, that is, when the modeling data acquired by the modeling data receiving unit 31 is pattern data of only the three-dimensional modeling material 15, the modeling data correction The unit 32 sends the modeling data acquired by the modeling data receiving unit 31 to the print control unit 33 without correcting the modeling data.

  On the other hand, when the three-dimensional structure 5 has an overhang portion, that is, when the modeling data acquired by the modeling data receiving unit 31 includes the pattern data of the three-dimensional modeling material 15 and the support material 16, the modeling data correction is performed. The unit 32 corrects the modeling data acquired by the modeling data receiving unit 31. The modeling data correction unit 32 generates corrected modeling data in which a gap is formed at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer based on the modeling data acquired by the modeling data receiving unit 31. Then, the modeling data correction unit 32 sends the generated corrected modeling data to the print control unit 33. Note that the gap is a gap for accommodating the extra three-dimensional modeling material 15 or the support material 16 generated when the roller R levels the three-dimensional modeling material 15 and the support material 16.

  Based on the modeling data or the corrected modeling data received from the modeling data correction unit 32, the print control unit 33 performs ink ejection (specifically, ink ejection, its ejection amount, its ejection force, etc.) by the inkjet head 21. Control to form each layer. The print control unit 33 controls the movement (scanning) of the carriage 23 at the same time as the ink ejection control by the inkjet head 21. Further, the print control unit 33 controls the flattening unit 20 (specifically, control of the flattening unit 20 moving (scanning) speed, the rotation speed of the roller R, etc.), and the layer is formed every time one layer is formed. To flatten. Then, the print control unit 33 controls the UV irradiation of the UV irradiation unit 22 and irradiates the layer flattened by the flattening unit 20 with ultraviolet rays, thereby curing the layer.

<Base 40>
The base 40 is a plate-like stage on which the ink ejected from the inkjet head 21 of the recording unit 10 is deposited. A three-dimensional structure 5 is formed on the base 40 as shown in FIG.

  A layer extending along the upper surface of the base 40 is formed by disposing the lower surface of the recording unit 10 on the upper surface of the base 40 so as to reciprocate the recording unit 10 in the Y-axis direction and ejecting ink during the movement. Can be stacked.

  In the present embodiment, the position of the base 40 is fixed and only the recording unit 10 is moved. However, the present invention is not limited to this. Since the relative position between the recording unit 10 and the base 40 may be changed in a predetermined direction, the recording unit 10 may move in a predetermined direction in the XYZ coordinate system, and the base 40 may be moved in the XYZ coordinate system. It may be moved in a predetermined direction, and either may be performed.

(Method for forming a three-dimensional structure)
A method for forming the three-dimensional structure 5 according to the present embodiment will be described with reference to FIGS. 4 and 5. FIG. 4 is a flowchart showing the flow of the method for forming the three-dimensional structure 5. Moreover, (a)-(c) in FIG. 5 is a figure which shows each process of the formation method of the three-dimensional structure 5. FIG.

  First, the modeling data receiving unit 31 of the control unit 30 acquires modeling data (step S1; hereinafter, abbreviated as “S1”), and sends the modeling data to the modeling data correction unit 32. Based on the modeling data received from the modeling data receiving unit 31, the modeling data correcting unit 32 determines whether or not an overhang portion exists in the three-dimensional model 5 to be formed (S2).

  When there is an overhang part in the three-dimensional structure 5 to be formed (S2, Yes), the modeling data correction unit 32 is based on the modeling data acquired by the modeling data receiving unit 31, and the three-dimensional modeling material 15 and the support material in each layer. Corrected modeling data in which a gap is formed at the boundary of 16 is generated (S3). Then, the modeling data correction unit 32 sends the generated corrected modeling data to the print control unit 33, and the print control unit 33 performs printing based on the corrected modeling data received from the modeling data correction unit 32 (S4).

  Specifically, the printing control unit 33 controls the recording unit 10 to form each layer based on the pattern data of each layer indicated by the corrected modeling data. As described above, in the corrected modeling data, a gap is formed at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer. Therefore, as shown in FIG. 5A, the recording unit 10 forms a single layer by forming a gap 17 at the boundary between the three-dimensional modeling material 15 and the support material 16.

  When the recording unit 10 forms one layer in accordance with the corrected modeling data, the flattening unit 20 uses the roller R to cause irregularities on the surfaces of the three-dimensional modeling material 15 and the support material 16 immediately after being discharged from the recording unit 10. Make it flat. Specifically, as shown in FIG. 5B, while the roller R rotates in the rotational direction B on the layer formed by the recording unit 10, it moves in the traveling direction A and pressurizes the layer. To make the thickness uniform. At this time, as the roller R travels, the support material 16 dragged downstream in the traveling direction A by the roller R is generated. However, the dragged support member 16 is drawn further downstream by the roller R and enters the gap 17. When the roller R continues to move, the three-dimensional modeling material 15 dragged to the downstream side in the traveling direction A by the roller R is generated as shown in FIG. However, the dragged three-dimensional modeling material 15 is similarly dragged further downstream by the roller R and enters the gap 17.

  As a result, the gap 17 formed at the boundary between the three-dimensional modeling material 15 and the support material 16 is filled with the three-dimensional modeling material 15 or the support material 16 dragged by the roller R, and FIG. ), A single layer having a uniform thickness can be obtained. In this way, by forming the gap 17 at the boundary between the three-dimensional modeling material 15 and the support material 16, the three-dimensional modeling material 15 and the support material 16 dragged by the roller R enter the gap 17, respectively. Further, it is possible to prevent the three-dimensional modeling material 15 and the support material 16 from being mixed at the boundary between them. Therefore, it is possible to prevent the surface of the three-dimensional structure 5 from being roughened by mixing the three-dimensional structure 15 and the support material 16 at the boundary between them, and the surface of the obtained three-dimensional structure 5 is smooth. become. Thus, the three-dimensional structure 5 with good surface quality is obtained by the method for forming the three-dimensional structure 5 according to this embodiment.

  In addition, when there is no overhang part in the three-dimensional structure 5 to be formed (S2, No), the support material 16 is not necessary for forming the three-dimensional structure 5. That is, in this case, the modeling data correction unit 32 does not need to generate corrected modeling data in which a gap is formed at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer. Therefore, the modeling data correction unit 32 sends the modeling data to the print control unit 33 without correcting the modeling data acquired by the modeling data receiving unit 31. Then, the print control unit 33 performs printing based on the modeling data received from the modeling data correction unit 32 (S4).

(Gap pattern)
6A and 6B are top views of the layers of the three-dimensional modeling material 15 and the support material 16 before flattening, and the shape of the gap 17 provided at the boundary between the three-dimensional modeling material 15 and the support material 16. It is a figure which shows an example.

  At the boundary between the three-dimensional modeling material 15 and the support material 16, the influence on the surface of the three-dimensional modeling object 5 due to the mixing of both causes the three-dimensional modeling material 15 dragged by the roller R to be wound on the support material 16 side. Appears prominently in cases. That is, when the three-dimensional structure 15 is positioned on the upstream side of the support material 16 in the traveling direction of the roller R, the influence on the surface of the three-dimensional structure 5 appears remarkably. This is because the three-dimensional modeling material 15 dragged by the roller R jumps out from the surface of the three-dimensional model 5, and the surface quality of the three-dimensional model 5 is drastically reduced.

  Therefore, as shown in FIG. 6A, when the left side of the drawing is the upstream side in the traveling direction of the roller R, at least the three-dimensional modeling material 15 is more upstream in the traveling direction of the roller R than the support material 16. It is preferable to provide a gap 17 at the boundary between the two positions. Thereby, in the process of flattening by the roller R, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R enters the gap 17, and the dragged three-dimensional modeling material 15 is It can prevent being caught in the support material 16 side. As a result, the three-dimensional modeling material 15 is mixed from the surface of the three-dimensional modeling object 5 at the boundary between the support material 16 and the portion located upstream of the support material 16 in the traveling direction of the roller R. The material 15 can be prevented from jumping out, and the three-dimensional structure 5 having a smooth surface can be formed. In this way, the three-dimensional structure 5 having a sufficiently good surface quality can be obtained even by forming the gap 17 at least at a part of the boundary between the three-dimensional structure material 15 and the support material 16 in one layer.

  Here, in the case of flattening by the roller R, in addition to the three-dimensional modeling material 15 dragged downstream by the roller R, the three-dimensional modeling material that is pushed by the roller R in a direction orthogonal to the traveling direction of the roller R. 15 also occurs. The 3D modeling material 15 that is spread in the direction orthogonal to the traveling direction of the roller R is also wound on the support material 16 side at the boundary between the 3D modeling material 15 and the support material 16, thereby It jumps out of the surface and deteriorates the surface quality of the three-dimensional structure 5.

  Therefore, as shown in FIG. 6B, a gap 17 may be formed over the entire boundary between the three-dimensional modeling material 15 and the support material 16 in one layer. Thereby, in the process of flattening by the roller R, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R and the tertiary expanded in the direction orthogonal to the traveling direction of the roller R. The original modeling material 15 enters the gap 17 and can prevent the three-dimensional modeling material 15 from being caught on the support material 16 side. In addition, since a gap 17 is formed at the boundary between the support material 16 and the location located upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R, in the process of flattening by the roller R, The support material 16 dragged to the downstream side in the traveling direction of the roller R by the roller R enters the gap 17, and the dragged support material 16 can be prevented from being caught on the three-dimensional modeling material 15 side. As a result, it is possible to prevent the surface of the three-dimensional structure 5 from becoming rough due to the mixing of both at the boundary between the three-dimensional structure material 15 and the support material 16, and the three-dimensional structure having a smooth surface. 5 can be formed.

  In the present embodiment, the three-dimensional modeling material 15 is ink for forming the three-dimensional modeling object 5 (that is, ink for model material and ink for decoration). Therefore, in FIG. 5A, FIG. 7 shows a diagram in which the model material ink and the decoration ink included in the three-dimensional modeling material 15 are clearly shown. As shown in FIG. 7, the formation of the gap 17 at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer means that the ink located at the outermost edge among the inks contained in the three-dimensional modeling material 15 in each layer (FIG. 7 means that a gap 17 is formed at the boundary between the transparent ink 14) and the support material 16.

  Although the example which forms the clearance gap 17 in a part or the whole of the boundary of the three-dimensional modeling material 15 in one layer and the support material 16 was shown above, this invention is not necessarily limited to this. As described above, the gap 17 may be formed in at least a part of the boundary between the three-dimensional modeling material 15 and the support material 16 in one layer. For example, a plurality of gaps 17 are formed at the boundary between the three-dimensional modeling material 15 and the support material 16. It may be formed.

(Gap width)
The suitable width of the gap 17 provided at the boundary between the three-dimensional modeling material 15 and the support material 16 is the viscosity of the ink (three-dimensional modeling material 15 and the support material 16) before curing, and wetting and spreading (wetting) of the ink onto the ink ejection target surface. Characteristics), the diameter and rotation speed of the roller R, the amount of ink removed by the flattening (the amount of ink dragged), the thickness of the layer after the flattening, the scanning speed of the carriage 23, and the amount of ink discharged by one scanning. Fluctuate accordingly. Therefore, the width of the gap 17 may be set to a width according to these conditions.

For example, using a three-dimensional modeling material 15 having a viscosity of 20 to 22 mPa · S, a roller R diameter of 30 mm, a rotation speed of the roller R of 370 rpm, an ink removal amount of 8 μm by flattening, a scanning speed of the carriage 23 of 28.2 mm / s, When the three-dimensional structure 5 is formed under the conditions that the layer thickness after flattening is 6 μm and the ink discharge amount is 0.1 / inch ² by one scanning, the width of the gap 17 is 0.05 to 0.1 mm. Is preferred. When the three-dimensional modeling material 15 having a viscosity of 32 to 34 mPa · S is used under the same conditions, the width of the gap 17 can be reduced by 10%.

  The preferable width of the gap 17 provided at the boundary between the three-dimensional modeling material 15 and the support material 16 is that all of the three-dimensional modeling material 15 or the support material 16 dragged by the roller R to the downstream side in the traveling direction of the roller R. It is the width that can enter. However, the present invention is not limited to this, and a part of the three-dimensional modeling material 15 or the support material 16 that is dragged by the roller R toward the downstream side in the traveling direction of the roller R enters. You may set to the width which can be.

  Regarding the position and width of the gap 17, setting values preset by the user may be stored in the control unit 30, or a program for calculating optimal setting values according to the various conditions described above may be stored in advance in the control unit 30. May be stored. The modeling data correction unit 32 may set the position and width of the gap 17 using the user setting value stored in the control unit 30 or the above program.

  Note that the three-dimensional modeling material 15 or the support material 16 dragged by the roller R to the downstream side in the traveling direction of the roller R is pushed out in a direction perpendicular to the traveling direction of the roller R. More than the amount. Therefore, in the case of FIG. 6B, the roller R is larger than the width (w1) of the gap 17 into which the three-dimensional modeling material 15 or the support material 16 dragged to the downstream side in the traveling direction of the roller R enters. The width (w2) of the gap 17 into which the three-dimensional modeling material 15 that is expanded in a direction orthogonal to the traveling direction of R enters may be smaller.

(Glossiness adjustment)
The three-dimensional modeling material 15 or the support material 16 that is dragged by the roller R toward the downstream side in the traveling direction of the roller R enters the gap 17 formed at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer. By setting the width sufficiently, the surface of the obtained three-dimensional structure 5 is smooth. Therefore, the three-dimensional structure 5 having a high surface glossiness, that is, a glossy surface is obtained.

  On the contrary, when the width of the gap 17 formed at the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer is reduced, the three-dimensional modeling material 15 or the support dragged by the roller R to the downstream side in the traveling direction of the roller R. The three-dimensional modeling material 15 or the support material 16 that does not fit in the gap 17 of the material 16 is generated. The 3D modeling material 15 or the support material 16 is respectively wound on the support material 16 side or the 3D modeling material 15 side, and the support material 16 is removed by mixing the 3D modeling material 15 and the support material 16. Unevenness is formed on the surface of the three-dimensional structure 5 obtained later. Therefore, the three-dimensional structure 5 having a low surface glossiness, that is, a mat-like surface is obtained.

  Thus, the glossiness of the surface of the finally obtained three-dimensional structure 5 can be adjusted by changing the width of the gap 17 formed at the boundary between the three-dimensional structure material 15 and the support material 16 in each layer. . Thereby, when it is desired to finish the surface of the three-dimensional structure 5 to a glossy surface, the width of the gap 17 formed at the boundary between the three-dimensional structure material 15 and the support material 16 in each layer is set to a sufficient size. By preventing the material 15 and the support material 16 from mixing, the three-dimensional structure 5 having a high glossiness can be produced. In addition, when finishing the surface of the three-dimensional structure 5 to be a matte surface, the width of the gap 17 formed at the boundary between the three-dimensional structure 15 and the support material 16 in each layer is narrowed, and the three-dimensional structure 15 and the support are formed. By intentionally mixing the material 16, the three-dimensional structure 5 having a low glossiness can be produced.

[Second Embodiment]
In the embodiment described above, the configuration in which the gap 17 is formed in at least a part of the boundary between the three-dimensional modeling material 15 and the support material 16 in one layer is shown, but the present invention is not necessarily limited thereto. Therefore, in this embodiment, a modification of the above-described embodiment is shown in FIG. FIG. 8 is a diagram illustrating a process in which the recording unit 10 forms one layer with the three-dimensional modeling material 15 and the support material 16.

(Method for forming a three-dimensional structure)
As shown in FIG. 8, the recording unit 10 may form a gap 17 (on the right side in the drawing) along the boundary between the three-dimensional modeling material 15 and the support material 16 in the three-dimensional modeling material 15. In this case, the modeling data correction unit 32 creates a gap 17 along the boundary between the three-dimensional modeling material 15 and the support material 16 in the three-dimensional modeling material 15 in each layer based on the modeling data acquired by the modeling data receiving unit 31. The formed corrected modeling data is generated. Then, the modeling data correction unit 32 sends the generated corrected modeling data to the printing control unit 33, and the printing control unit 33 performs printing based on the received corrected modeling data.

  As shown in FIG. 5A, when a gap 17 is formed at the boundary between the three-dimensional modeling material 15 and the support material 16 to form one layer, the right gap 17 in FIG. As a result, the three-dimensional modeling material 15 dragged to the downstream side in the traveling direction of the roller R enters. Therefore, in the gap 17 portion on the right side in the figure, the three-dimensional modeling material 15 that has flowed into the gap 17 forms the outermost layer (outermost circumference) of the three-dimensional structure 5. Therefore, the edge of the outermost layer (outermost circumference) of the three-dimensional structure 5 in the right-side gap 17 in the figure has a slightly rounded shape.

  On the other hand, as shown in FIG. 8, a gap 17 (on the right side in the figure) along the boundary between the three-dimensional modeling material 15 and the support material 16 is formed in the three-dimensional modeling material 15 to form one layer. Is formed, the three-dimensional modeling material 15 is formed on the surface layer side (outer peripheral side) from the gap 17. Therefore, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R enters the gap 17 on the right side in the figure, but the dragged three-dimensional modeling material 15 is inserted. Does not form the outermost layer (outermost circumference) of the three-dimensional structure 5. Since the 3D modeling material 15 formed on the surface layer side (outer peripheral side) than the gap 17 on the right side in the figure forms the outermost layer (outermost circumference) of the three-dimensional model 5, the right side in the figure The edge of the outermost layer (outermost periphery) of the three-dimensional structure 5 in the gap 17 portion can have a radius of curvature smaller than that in the case of FIG.

(Gap pattern)
FIGS. 9A and 9B are top views of layers of the three-dimensional modeling material 15 and the support material 16 before flattening, and the three-dimensional modeling material 15 and the support material provided in the three-dimensional modeling material 15. It is a figure which shows the example of the shape of the clearance gap 17 along the boundary of 16. FIG.

  In FIG. 8, the left gap 17 in the drawing is formed at the boundary between the three-dimensional modeling material 15 and the support material 16. In this case, the support material 16 dragged by the roller R toward the downstream side in the traveling direction of the roller R enters the gap 17 and forms the outermost layer (outermost periphery) of the three-dimensional structure 5. The three-dimensional modeling material 15 is a three-dimensional modeling material 15 formed adjacent to the gap 17. Therefore, the edge of the outermost layer (outermost circumference) of the three-dimensional structure 5 in the left gap 17 portion in the drawing is the edge of the outermost layer (outermost circumference) of the three-dimensional structure 5 in the right gap 17 portion in the drawing. It becomes a square edge like

  Thus, when the outermost layer (outermost circumference) of the three-dimensional structure 5 is formed by the three-dimensional structure 15 dragged by the roller R to the downstream side in the traveling direction of the roller R, the outermost surface layer. The (outermost) edge has a slightly rounded shape. That is, when the three-dimensional structure 15 is positioned upstream of the support member 16 in the traveling direction of the roller R, when the outermost layer (outermost circumference) of the three-dimensional structure 5 is formed, the outermost layer The (outermost) edge has a slightly rounded shape.

  Therefore, as shown in FIG. 9A, when the left side of the drawing is the upstream side in the traveling direction of the roller R, at least the three-dimensional modeling material 15 is more upstream in the traveling direction of the roller R than the support material 16. It is preferable to provide a gap 17 along the boundary between the two positions in the three-dimensional modeling material 15. Thereby, in the process of flattening by the roller R, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R enters the gap 17, but on the surface layer side (outer periphery) from the gap 17. The three-dimensional structure 15 formed on the side) forms the outermost layer (outermost periphery) of the three-dimensional structure 5. Therefore, the edge of the outermost layer (outermost periphery) of the three-dimensional structure 5 in the right gap 17 portion in the drawing can be a square edge with a small curvature radius. In this way, the gap 17 may be formed in at least a portion along the boundary between the three-dimensional modeling material 15 and the support material 16 in the one-dimensional three-dimensional modeling material 15.

  Here, as described above, when flattening by the roller R, in addition to the three-dimensional modeling material 15 dragged downstream by the roller R, the roller R spreads in a direction perpendicular to the traveling direction of the roller R. A three-dimensional modeling material 15 is also produced. Since the three-dimensional modeling material 15 that is spread in the direction orthogonal to the traveling direction of the roller R also forms the outermost layer (outermost circumference) of the three-dimensional structure 5, the edge of the outermost layer (outermost circumference) The shape is slightly rounded.

  Therefore, as shown in FIG. 9B, a gap 17 is formed in the entire portion along the boundary between the three-dimensional modeling material 15 and the support material 16 in the three-dimensional modeling material 15 of one layer. Also good. Thereby, in the process of flattening by the roller R, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R and the tertiary expanded in the direction orthogonal to the traveling direction of the roller R. The original modeling material 15 enters the gap 17, but the three-dimensional modeling material 15 formed on the surface layer side (outer peripheral side) than the gap 17 forms the outermost layer (outermost periphery) of the three-dimensional modeled object 5. Become. As a result, the entire edge of the outermost layer (outermost circumference) of the three-dimensional structure 5 can be formed into a square edge having a small curvature radius.

  In the present embodiment, the three-dimensional modeling material 15 is ink for forming the three-dimensional modeling object 5 (that is, ink for model material and ink for decoration). Therefore, in FIG. 9A, a diagram clearly showing the model material ink and the decoration ink included in the three-dimensional modeling material 15 is shown in FIG. As shown in (a) of FIG. 10, as an example of forming the gap 17 along the boundary between the three-dimensional modeling material 15 and the support material 16 in each layer in the three-dimensional modeling material 15, Among the included inks, the ink located at the outermost end (transparent ink 14 in the case of FIG. 10A) and the ink adjacent to the ink (decorative ink 13 in the case of FIG. 10A) The case where the clearance gap 17 is formed in the boundary with) can be mentioned.

  However, the present invention is not limited to this, and a gap 17 may be formed at the boundary between the model material 11 and the white ink 12, or the gap 17 may be formed at the boundary between the white ink 12 and the decorative ink 13. It may be formed. That is, the gap 17 can be formed at the boundary between two adjacent inks among the inks included in the three-dimensional modeling material 15 in one layer. In addition, a gap 17 along the boundary between the three-dimensional modeling material 15 and the support material 16 can be formed in one of the inks included in the three-dimensional modeling material 15 in one layer.

  Forming the gap 17 at the boundary between the model material 11 and the white ink 12 or the boundary between the white ink 12 and the decorative ink 13 is preferable even when the three-dimensional structure 5 having no overhang portion is formed. is there. This is because the model material 11 dragged by the roller R is wound on the white ink 12 side or the decorative ink 13 side, or the white ink 12 dragged by the roller R is wound on the decorative ink 13 side. This is because these inks can be prevented from mixing at the boundary between the model material 11 and the white ink 12 or at the boundary between the white ink 12 and the decorative ink 13.

  Therefore, in the method for forming the three-dimensional structure 5 according to the present invention, the three-dimensional structure is formed by laminating layers of at least two types of ink among the ink for model material, the ink for decoration, and the ink for support material. In other words, the gap 17 is formed in at least one part of the boundary between two adjacent inks in one layer and at least one part along the boundary. .

  FIG. 10A shows an example in which one gap 17 is formed along the boundary between the three-dimensional modeling material 15 and the support material 16 in the three-dimensional modeling material 15 of one layer. It is not necessarily limited to this. As described above, the gap 17 may be formed in at least a part of the one-layer three-dimensional modeling material 15 along the boundary between the three-dimensional modeling material 15 and the support material 16, for example, as shown in FIG. As described above, a plurality of gaps 17 along the boundary between the three-dimensional modeling material 15 and the support material 16 in the three-dimensional modeling material 15 of one layer may be formed. Further, as shown in the figure, a gap 17 can also be formed at the boundary between the three-dimensional modeling material 15 and the support material 16. That is, the gap 17 may be formed in at least one part of the boundary between the three-dimensional modeling material 15 and the support material 16 in one layer and at least one part along the boundary in the three-dimensional modeling material 15.

(Gap width)
As described above, the preferred width of the gap 17 provided at the boundary between the three-dimensional modeling material 15 and the support material 16 is the viscosity of the ink (three-dimensional modeling material 15 and the support material 16) before curing, and the ink ejection target surface of the ink. Spread (wetability), roller R diameter and rotation speed, ink removal amount by flattening (amount of dragged ink), layer thickness after flattening, scanning speed of carriage 23, and ink ejection by one scan It fluctuates according to conditions such as quantity. Therefore, the width of the gap 17 may be set to a width according to these conditions, for example, 0.1 to 0.3 mm.

[Third Embodiment]
When the support material 16 is positioned upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R, in the process of flattening by the roller R, as the roller R proceeds, the roller R moves downstream in the traveling direction. The support material 16 to be dragged is generated, and the surface of the three-dimensional structure 5 becomes rough due to the support material 16 wound on the three-dimensional structure material 15 side. In this case, it is preferable to form the gap 17 at the boundary between the support material 16 and the portion along the boundary at the position located upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R.

  Thereby, in the process of flattening by the roller R, the support material 16 dragged by the roller R to the downstream side in the traveling direction of the roller R enters the gap 17, and the dragged support material 16 becomes the three-dimensional modeling material. The three-dimensional structure 5 having a smooth surface can be formed because it can be prevented from being caught on the 15 side.

  Here, FIG. 11 shows an example of the position of the gap 17 in the case where the gap 17 is provided at a location where the support material 16 is located upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R. As shown in FIG. 11A, when the left side of the drawing is the upstream side in the traveling direction of the roller R, the support material 16 is upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R in one layer. You may form the clearance gap 17 in the boundary of both in the location located in the side.

  Alternatively, as illustrated in FIG. 11B, when the left side of the drawing is the upstream side in the traveling direction of the roller R, the support material 16 is in the traveling direction of the roller R rather than the three-dimensional modeling material 15 in one layer. A gap 17 may be provided in the support member 16 along the boundary between the two at a location located on the upstream side.

  In this case, the support material 16 is formed on the inner side (center side) of the gap 17 along the boundary between both of the support material 16 at a position located upstream of the three-dimensional modeling material 15 in the traveling direction of the roller R. Has been. Therefore, the three-dimensional modeling material 15 that forms the outermost layer (outermost circumference) of the three-dimensional structure 5 is discharged adjacent to the support material 16 formed on the inner side (center side) than the gap 17. It will be. As a result, the entire edge of the outermost layer (outermost periphery) of the three-dimensional structure 5 can be formed into a square edge having a smaller curvature radius.

[Fourth Embodiment]
The present invention is applicable even when the three-dimensional structure to be formed has a hollow structure. Accordingly, a case where a three-dimensional structure having a hollow structure is formed will be described with reference to FIG. FIG. 12 is a diagram illustrating a three-dimensional structure formed in the present embodiment. (A) of FIG. 12 is an external view of a three-dimensional structure, and (b) of FIG. 12 is a view showing a cross section taken along the cutting line AA ′ of (a) of FIG.

  A three-dimensional structure 5a shown in FIG. 12 (a) has a shape of a quadrangular prism having an open bottom and a hollow shape. As shown in FIG. 12B, the three-dimensional structure 5a is formed by covering the modeling layer 1 with the modeling layer 1, the light reflection layer 2, the color layer 3 and the transparent layer 4 in this order. .

  The hollow part of the three-dimensional structure 5a shown in FIG. 12 has a structure (overhang) in which the end on the hollow part side of the upper layer protrudes from the end part on the hollow part side of the lower layer among the two upper and lower layers stacked. ). Therefore, the support material 16 is formed adjacent to the outer peripheral end of the lower layer of the three-dimensional modeling material 15, and the overhang portion of the upper layer is formed of the three-dimensional modeling material 15 on the support material 16. That is, by forming a region corresponding to the hollow portion of the three-dimensional structure 5a with the support material and then removing the support material 16, a hollow portion is formed in the three-dimensional structure 5a.

  In FIG. 13, the example of the position of the clearance gap provided when forming the three-dimensional structure 5a of a hollow structure is shown. As shown in FIG. 13A, when forming a three-dimensional structure 5a having a hollow structure, the support material 16 is discharged between the three-dimensional structure 15 and the three-dimensional structure 15 in one layer. Will be.

  Therefore, as shown in FIG. 13A, when the left side of the drawing is the upstream side in the traveling direction of the roller R, the three-dimensional modeling material 15 is located upstream of the support material 16 in one layer. The gap 17 may be formed at the boundary between the two, and the gap 17 may be formed at the boundary between the support material 16 at the upstream side of the three-dimensional modeling material 15.

  Thereby, in the process of flattening by the roller R, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction is dragged further downstream by the roller R in the drawing. It enters the gap 17 on the left side of. When the roller R continues to move, the support member 16 dragged by the roller R to the downstream side in the traveling direction is similarly dragged further downstream by the roller R and enters the right gap 17 in the drawing.

  Thus, since the three-dimensional modeling material 15 and the support material 16 dragged during the flattening enter the gap 17, respectively, the dragged three-dimensional modeling material 15 and the support material 16 are mixed at the boundary between them. Can be prevented. Therefore, it is possible to prevent the surface of the three-dimensional structure 5a from becoming rough due to the mixing of the three-dimensional structure 15 and the support material 16 at the boundary between them, and the surface of the obtained three-dimensional structure 5a is smooth. become. Thus, even when the three-dimensional structure 5a having a hollow structure is formed, the three-dimensional structure 5a having a good surface quality can be obtained.

  Alternatively, as illustrated in FIG. 13B, when the left side of the drawing is the upstream side in the traveling direction of the roller R, the three-dimensional modeling material 15 is located upstream of the support material 16 in one layer. A gap 17 along the boundary between the two is formed in the three-dimensional modeling material 15, and the gap 17 along the boundary between the two at the position where the support material 16 is located upstream of the three-dimensional modeling material 15. You may form in.

  As a result, the three-dimensional modeling material 15 is formed on the surface layer side of the gap 17 on the left side in the drawing. Therefore, the three-dimensional modeling material 15 dragged by the roller R to the downstream side in the traveling direction of the roller R enters the gap 17 on the left side in the figure, but the dragged three-dimensional modeling material 15 is inserted. Does not form the outermost layer of the three-dimensional structure 5. Since the three-dimensional modeling material 15 formed on the surface layer side of the left gap 17 in the figure forms the outermost layer of the three-dimensional model 5, the three-dimensional modeling of the left gap 17 portion in the figure The edge of the outermost layer of the object 5 is a square edge with a small radius of curvature.

  In addition, the three-dimensional modeling material 15 that forms the outermost layer of the three-dimensional structure 5 is discharged adjacent to the support material 16 that is formed on the outer side (outer peripheral side) of the right gap 17 in the drawing. become. As a result, the entire edge of the outermost layer of the three-dimensional structure 5 can be a square edge with a smaller curvature radius.

[Summary]
The method for forming the three-dimensional structure 5 according to one embodiment of the present invention includes model material ink (model material 11 and white ink 12), decorative ink (decorative ink 13 and transparent ink 14), and support material. A method for forming a three-dimensional structure 5 in which layers of at least two types of ink among support inks (support material 16) are laminated, wherein one layer is formed by ejecting the at least two types of ink. And a planarizing member (roller R) moving in the first direction while leveling the ink on the surface, on the surface of the one layer formed in the forming step, Flattening step of flattening the surface of one layer, and in the forming step, at least a part of a boundary between two kinds of adjacent inks in the one layer and a small amount along the boundary. At least one of Kutomo portion, and forming a gap 17 for accommodating excess of the ink caused when the leveling of the ink in the planarization process.

  According to the above method, since the ink dragged during the flattening enters the gap 17, it is possible to prevent the dragged ink from being mixed at the boundary between the ink and the adjacent ink. Therefore, it is possible to prevent the surface quality of the three-dimensional structure 5 from being deteriorated by mixing two kinds of adjacent inks at the boundary between them. Thus, the three-dimensional structure 5 having good surface quality is obtained by the method for forming the three-dimensional structure 5 according to one aspect of the present invention.

  In the formation method of the three-dimensional structure 5 according to an aspect of the present invention, in the formation step, at least one of the model material ink and the decoration ink and the support material ink are ejected. One layer is formed, and in the one layer, at least one of the model material ink and the decoration ink is located at a position located upstream of the support material ink in the first direction. The gap 17 is formed in at least one part of the boundary between the two and at least one part along the boundary in the ink that is located upstream of the support material ink in the first direction.

  According to the above method, in the process of flattening by the flattening member, the ink dragged by the flattening member to the downstream side in the traveling direction of the flattening member enters the gap 17, and the dragged ink is supported. The three-dimensional structure 5 having a smooth surface can be formed because it can be prevented from being caught on the material ink side.

  In the formation method of the three-dimensional structure 5 according to an aspect of the present invention, in the formation step, at least one of the model material ink and the decoration ink and the support material ink are ejected. 1 layer is formed, and in the one layer, the support material ink is located at a position upstream of at least one of the model material ink and the decoration ink in the first direction. The gap 17 is formed in at least one part of the boundary between the two and at least one part along the boundary in the support material ink.

  According to the above method, in the process of flattening by the flattening member, the support material ink dragged by the flattening member to the downstream side in the traveling direction of the flattening member enters the gap 17 and is dragged. The support material ink can be prevented from being caught on the ink side adjacent to the support material ink, and the three-dimensional structure 5 having a smooth surface can be formed.

  The method for forming a three-dimensional structure 5 according to one aspect of the present invention is such that, in the forming step, the entire boundary between the two adjacent inks in the one layer, or the entire portion along the boundary. The gap 17 is formed.

  According to said method, it can prevent that the surface quality of the three-dimensional structure 5 deteriorates by mixing both in the whole boundary of two types of adjacent ink, and has favorable surface quality. A three-dimensional structure 5 can be formed.

  In the method for forming the three-dimensional structure 5 according to one aspect of the present invention, in the forming step, the one ink layer is ejected from the model material ink, the decoration ink, and the support material ink. In the one layer, the decorative ink is downstream of the model material ink in the first direction and upstream of the support material ink in the first direction. The gap 17 is formed in at least a part of the boundary between the decorative ink and the support material ink at a location located on the side.

  According to the above method, by forming the gap 17 at the boundary between the decorative ink and the support material ink, the model material ink or the decorative ink dragged during the planarization enters the gap 17. Therefore, it is possible to prevent the dragged model material ink or decoration ink and support material ink from being mixed at the boundary. Therefore, the surface of the obtained three-dimensional structure 5 becomes smooth, and the three-dimensional structure 5 with good surface quality is obtained.

In the forming method of the three-dimensional structure 5 according to one aspect of the present invention, in the forming step,
The model material ink, at least one kind of the decoration ink, and the support material ink are ejected to form the one layer. In the one layer, at least one kind of the decoration material is used. The boundary between the adjacent model material ink and the decorative ink at the location where the ink is located downstream of the model material ink in the first direction, or two adjacent types of the decorative ink. The gap 17 is formed in at least a part of the boundary.

  According to the above method, since the gap 17 is formed at the boundary between the adjacent ink for the model material and the decorative ink, or the boundary between the two types of the adjacent decorative ink, the surface layer side from the gap 17 A decorative ink is formed on the outer peripheral side. Therefore, the decorative ink formed on the surface layer side (outer periphery side) than the gap 17 forms the outermost layer (outermost periphery) of the three-dimensional structure 5. Therefore, the edge of the outermost layer (outermost circumference) of the three-dimensional structure 5 can be a square edge with a small radius of curvature, and the three-dimensional structure 5 with better surface quality can be obtained.

  In the formation method of the three-dimensional structure 5 according to an aspect of the present invention, in the formation step, at least one of the model material ink and the decoration ink and the support material ink are ejected. One layer is formed, and the gap is formed in at least part of the boundary between the ink for the support material and the ink for the support material adjacent to the ink for the support material in the one layer, and is formed in the forming step. By adjusting the width of the gap 17, the glossiness of the surface of the three-dimensional structure is adjusted.

  According to the above method, by changing the width of the gap formed at the boundary between the ink for the support material in each layer and the ink adjacent to the ink for the support material, the surface of the finally obtained three-dimensional structure 5 can be obtained. Glossiness can be adjusted.

  The present invention is not limited to the above-described embodiments, and various modifications are possible within the scope shown in the claims, and embodiments obtained by appropriately combining technical means disclosed in different embodiments. Is also included in the technical scope of the present invention.

  INDUSTRIAL APPLICABILITY The present invention can be suitably used for manufacturing a model, an industrial product, a toy, etc. in a field where it is necessary to produce a three-dimensional structure such as medical, architectural, or toy fields.

DESCRIPTION OF SYMBOLS 1 Modeling layer 2 Light reflection layer 3 Color layer 4 Transparent layer 5 Three-dimensional modeling object 10 Recording unit 11 Model material 12 White ink 13 Decorating ink 14 Transparent ink 15 Three-dimensional modeling material 16 Support material 17 Gap 20 Flattening unit 21 Inkjet Head 22 UV irradiation unit 23 Carriage 30 Control unit 31 Modeling data receiving unit 32 Modeling data correcting unit 33 Print control unit 40 Base 50 Forming device

Claims (7)

Among the ink for model material, the ink for decoration, and the ink for support material, a method for forming a three-dimensional structure formed by laminating and forming layers composed of at least two types of inks,
Forming the one layer by discharging the at least two types of ink;
Flattening that flattens the surface of the one layer by moving the flattening member in the first direction while leveling the ink on the surface on the surface of the one layer formed in the forming step. Including a process,
The forming step occurs when the ink is leveled in the flattening step on at least a part of a boundary between two adjacent inks in the one layer and at least a part along the boundary. A method for forming a three-dimensional structure, characterized by forming a gap for accommodating excess ink. In the formation process,
Discharging at least one of the model material ink and the decorative ink and the support material ink to form the one layer;
In the one layer, at least one of the boundary between the at least one of the model material ink and the decorative ink at a position located upstream of the support material ink in the first direction, and the The gap is formed in at least one of at least a part along the boundary in the ink located upstream of the support material ink in the first direction. A method for forming a three-dimensional structure. In the formation process,
Discharging at least one of the model material ink and the decorative ink and the support material ink to form the one layer;
In the one layer, at least a part of a boundary between the support material ink at a position located upstream of at least one of the model material ink and the decorating ink in the first direction, and the above The method for forming a three-dimensional structure according to claim 1, wherein the gap is formed in at least one of at least a portion along the boundary in the support material ink.   4. The method according to claim 1, wherein, in the forming step, the gap is formed in the entire boundary between the two adjacent inks in the one layer, or in the entire portion along the boundary. The method for forming a three-dimensional structure according to claim 1. In the formation process,
The model material ink, the decorative ink, and the support material ink are ejected to form the one layer.
In the one layer, the decorative ink is located downstream of the model material ink in the first direction and upstream of the support material ink in the first direction. The method for forming a three-dimensional structure according to claim 2, wherein the gap is formed in at least a part of a boundary between the decoration ink and the support material ink. In the formation process,
The model material ink, at least one kind of the decoration ink, and the support material ink are ejected to form the one layer.
In the one layer, at least one of the decorative inks is adjacent to the model material ink and the decorative ink at a location located downstream of the model material ink in the first direction. The method for forming a three-dimensional structure according to claim 2, wherein the gap is formed at least at a part of a boundary or a boundary between two kinds of the decorative inks adjacent to each other. In the formation process,
Discharging at least one of the model material ink and the decorative ink and the support material ink to form the one layer;
Forming the gap in at least part of the boundary between the ink for the support material in the one layer and the ink adjacent to the ink for the support material,
The tertiary of any one of claims 1 to 6, wherein the glossiness of the surface of the three-dimensional structure is adjusted by adjusting the width of the gap formed in the forming step. Forming method of original model.

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