JP4888236B2 - 3D modeling apparatus and 3D modeling method - Google Patents

Description

  The present invention relates to a technique for modeling a three-dimensional object, and more particularly, to a technique for modeling a three-dimensional object by discharging a binding liquid and combining powder materials.

  A technique for forming a three-dimensional object while solidifying a powder with a binding 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 to each other by discharging a binding liquid to a desired portion of the powder layer. As a result, in the powder layer, only the portion where the binding liquid is 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 formed on the powder layer, and the binding liquid is 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 binding liquid has been discharged. At this time, since the binding liquid discharged onto the powder layer soaks and reaches the previously formed cross-sectional member, the newly formed cross-sectional member is also bonded to the previously formed cross-sectional member. By repeating such operations and laminating thin plate-like cross-sectional members one by one, a three-dimensional object can be formed.

  With such 3D modeling technology, as long as there is 3D shape data of the object to be modeled, it is possible to immediately model by combining powder, and there is no need to create a mold prior to modeling. 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. .

  Alternatively, when forming a powder layer, by changing the type of powder depending on the region, it has also been proposed to form an object as if multiple parts of different materials were assembled as an integrated model. (Patent Document 1). Furthermore, since a transparent shaped product can be obtained by combining transparent powders (for example, Patent Document 2), by forming a partial region of the powder layer using transparent powder, it is as if glass It is considered possible to form an object that has been formed by fitting as an integrated model.

JP 2002-307562 A Japanese Patent Laying-Open No. 2005-088392

  However, with these proposed techniques, it is possible to make a part of a model transparent, but it has been difficult to provide sufficient transparency. For this reason, for example, an object (for example, an optical lens or an optical waveguide) in which a member having high optical characteristics (for example, high transparency, an accurate refractive index, etc.) is inserted, such as an optical component such as a lens or a prism. Etc.), a separately formed member (for example, an optical component) had to be fitted.

  The present invention has been made to solve the above-mentioned problems of the prior art, and can be formed as an integrated model even if a part of the model has sufficient transparency like an optical component. The purpose is to provide 3D modeling technology.

In order to solve at least a part of the problems described above, the first three-dimensional modeling apparatus of the present invention employs the following configuration. That is,
A three-dimensional modeling apparatus that models a three-dimensional object by bonding powders together with a binding liquid,
Shape data storage means for storing shape data of a three-dimensional object having a transparent portion;
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;
The powder is spread to a substantially uniform thickness to form a powder layer, and the binding liquid is supplied to the powder layer according to the cross-sectional data, thereby corresponding to the cross-sectional shape of one layer of the three-dimensional object. Cross-sectional member forming means for forming a cross-sectional member to be
A new powder layer is formed on the powder layer on which the cross-sectional member is formed, and a new cross-sectional member is formed by supplying the binding liquid to the new powder layer according to the cross-sectional data. 3D object modeling means for modeling the 3D object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member,
The cross-section member forming means, when forming the cross-section member, for the portion determined to be transparent based on the cross-section data, instead of the powder layer, the binding liquid and a hardening liquid that cures the binding liquid And a means for forming the cross-sectional member by curing the binding liquid.

Moreover, the first 3D modeling method of the present invention corresponding to the 3D modeling apparatus described above is
A three-dimensional modeling method for modeling a three-dimensional object by bonding powders together with a binding liquid,
A shape data storage step storing shape data of a three-dimensional object having a transparent portion;
A cross-section data generation step for generating cross-section data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections;
The powder is spread to a substantially uniform thickness to form a powder layer, and the binding liquid is supplied to the powder layer according to the cross-sectional data, thereby corresponding to the cross-sectional shape of one layer of the three-dimensional object. A cross-section member forming step for forming a cross-section member to be performed;
A new powder layer is formed on the powder layer on which the cross-sectional member is formed, and a new cross-sectional member is formed by supplying the binding liquid to the new powder layer according to the cross-sectional data. A three-dimensional object modeling step of modeling the three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member,
In the cross-section member forming step, when forming the cross-section member, for the portion determined to be transparent based on the cross-section data, instead of the powder layer, the binding liquid and a curable liquid for curing the binding liquid The gist of the present invention is the step of forming the cross-sectional member by supplying the

  In the first three-dimensional modeling apparatus and the first three-dimensional modeling method of the present invention, shape data of a three-dimensional object to be modeled is stored in advance, and the three-dimensional object is layered in a plurality of cross sections. It is possible to generate cross-sectional data at each layer when cut. Then, the powder is spread to a substantially uniform thickness to form a powder layer, and the binding liquid is supplied to the powder layer according to the cross-sectional data. When the binding liquid is supplied, the powders are bonded to each other. Therefore, by supplying the binding liquid to the powder layer according to the cross-sectional data, 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 (a cross-sectional member) can be formed. Therefore, a new powder layer is formed on the powder layer on which the cross-sectional member is formed, and a binding liquid is supplied to the powder layer according to the cross-sectional data, thereby forming a new cross-sectional member. It is laminated on the cross-sectional member formed previously. By repeating such an operation, a three-dimensional object can be formed. Here, in the case where a transparent part exists in the three-dimensional object to be shaped, when forming the cross-sectional member, the part determined to be transparent from the cross-sectional data is replaced with the binding liquid instead of the powder layer. The transparent liquid of the cross-sectional member is formed by supplying a hardening liquid for hardening the binding liquid and hardening the binding liquid.

  Since each powder is an individual, even if the powders are bonded together with a binding liquid, a boundary surface is generated between the powders and between the powders and the binding liquid. There are innumerable boundary surfaces inside the shaped 3D object. For this reason, even if each powder is made of a transparent material, light is irregularly reflected at innumerable boundary surfaces inside the three-dimensional object, and it is difficult to obtain high transparency. Alternatively, it is difficult to obtain an accurate refractive index because light is refracted in a complicated manner when passing through an infinite number of boundary surfaces. On the other hand, if the liquid binding liquid is cured using the same liquid curing liquid, no boundary surface is generated, and such a problem does not occur. The first three-dimensional modeling apparatus and the first three-dimensional modeling method of the present invention are based on such a principle, and instead of the powder layer, the portion determined to be transparent based on the cross-sectional data. A cross-section member is formed by supplying a binding liquid and a curing liquid and curing the binding liquid, and a three-dimensional object is formed by stacking the cross-section members thus formed. In this way, by selecting an appropriate curing liquid or binding liquid in advance, a transparent part has a high transparency, or a three-dimensional object having an accurate refractive index is modeled as an integrated model. It becomes possible. In addition, when the three-dimensional object is an object having a transparent part on the surface part, the surface part is formed by a binding liquid (and a hardening liquid), so that it is more homogeneous than when formed using powder. A dense surface can be obtained.

  In the first three-dimensional modeling apparatus of the present invention, the cross-sectional member may be formed as follows. First, a powder layer is formed over the entire surface (that is, regardless of whether or not it is transparent). Next, for the portion determined to be transparent based on the cross-sectional data, the formed powder layer may be removed, and a cross-sectional member may be formed by supplying a binding liquid and a curing liquid to the removed portion. .

  When forming a cross-section member, it is possible to determine whether there is a transparent part, and if there is a transparent part, which part is transparent based on the cross-sectional data. It is also possible to leave without forming a powder layer from the beginning. However, if the powder layer is first formed on the entire surface including the transparent part and then the powder layer is removed only on the transparent part, the mechanism for forming the powder layer is very simple. It is possible to keep it in a safe place. In addition, it is easier to remove the powder layer in the transparent part than not to form a powder layer in the transparent part, and the transparent part and other parts are clearer A powder layer divided into two can be formed. For this reason, it is possible to obtain a three-dimensional object in which the boundary (or surface) of the transparent portion is clearly separated.

  Furthermore, in the first three-dimensional modeling apparatus of the present invention, the powder layer in the transparent portion may be removed as follows. First, a binding liquid is supplied around a portion determined to be transparent based on the cross-sectional data (that is, a portion from which the powder layer is removed), and the powders in the portion are bonded to each other. Then, you may make it remove the powder layer of a transparent part.

  Since the binding liquid can be supplied to the correct position, by supplying the binding liquid before removing the powder layer in the transparent part, the powder in the transparent part is not bound and the surrounding powder is bound. Can be made. And if the powder layer of a transparent part is removed after that, the powder layer of a transparent part can be removed completely, without removing surrounding powder. For this reason, since the transparent part is completely cured only by the binding liquid and the curing liquid, it is possible to obtain a three-dimensional object in which the transparent part is more transparent.

In order to solve at least a part of the problems described above, the second three-dimensional modeling apparatus of the present invention employs the following configuration. That is,
A three-dimensional modeling device that forms a three-dimensional object by supplying a light curable liquid that cures when irradiated with light to a modeled object by powder, and then irradiating light to bond the powders together. There,
Shape data storage means for storing shape data of a three-dimensional object having a transparent portion;
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;
The powder is spread to a substantially uniform thickness to form a powder layer, and the photo-curing liquid is supplied to the powder layer in accordance with the cross-sectional data, and then cured by irradiation with light, whereby the tertiary A cross-section member forming means for forming a cross-section member corresponding to the cross-sectional shape of one layer of the original object;
A new cross-sectional member is formed by forming a new powder layer on the powder layer on which the cross-sectional member is formed, supplying the photo-curing liquid to the new powder layer according to the cross-sectional data, and curing it. A three-dimensional object modeling means for modeling the three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member, and
The cross-section member forming means supplies the photo-curing liquid instead of the powder layer to the photo-curing liquid for the portion determined to be transparent based on the cross-section data when forming the cross-section member. The gist of the present invention is a means for forming the cross-sectional member by irradiating with light and curing.

Moreover, the second 3D modeling method of the present invention corresponding to the 3D modeling apparatus described above,
A three-dimensional modeling method that forms a three-dimensional object by supplying a light curable liquid that cures when irradiated with light to a modeled object with powder, and then irradiating light to bond the powders together. There,
A shape data storage step storing shape data of a three-dimensional object having a transparent portion;
A cross-section data generation step for generating cross-section data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections;
The powder is spread to a substantially uniform thickness to form a powder layer, and the photo-curing liquid is supplied to the powder layer in accordance with the cross-sectional data, and then cured by irradiation with light, whereby the tertiary A cross-section member forming step of forming a cross-section member corresponding to the cross-sectional shape of one layer of the original object;
A new cross-sectional member is formed by forming a new powder layer on the powder layer on which the cross-sectional member is formed, supplying the photo-curing liquid to the new powder layer according to the cross-sectional data, and curing it. Forming a three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member, and forming a three-dimensional object,
In the cross-section member forming step, when forming the cross-section member, the photo-curing liquid is supplied instead of the powder layer for a portion determined to be transparent based on the cross-section data. The gist of the present invention is the step of forming the cross-sectional member by irradiating light to the substrate and curing it.

  In the second three-dimensional modeling apparatus and the second three-dimensional modeling method of the present invention, after supplying a light curable liquid that is cured by light irradiation to the powder layer, the powder is irradiated with light. A cross-section member is formed by joining bodies together. In addition, when the cross-sectional member to be formed includes a transparent portion, the cross-sectional member is supplied to the portion by supplying a photo-curing liquid instead of the powder layer and then irradiating and curing the light. Form.

  By doing so, it is possible to form a three-dimensional object in which the transparent portion is formed only by the photocuring liquid. Since the transparent portion is formed only from the photocuring liquid, high transparency can be obtained. It is also possible to give an accurate refractive index by selecting an appropriate photocuring liquid. In addition, when the three-dimensional object is an object having a transparent portion on the surface portion, the surface portion is formed by the photo-curing liquid, so the surface is more uniform and dense than when formed using powder. Can be obtained.

Hereinafter, in order to clarify the contents of the present invention described above, examples will be described in the following order.
A. Device configuration:
B. Modeling method of this example:
C. Variation:
C-1. First modification:
C-2. Second modification:

A. Device configuration:
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 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. Arithmetic processing for performing various arithmetic processes in order to control the overall operation of the layer forming unit 20, the binding liquid supply unit 30 for supplying a binding liquid for bonding powders to the powder layer, and the three-dimensional modeling apparatus 100. The unit 40 is 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 that controls the operation of the modeling unit 10, the powder layer forming unit 20, and the binding liquid supply unit 30 in accordance with 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 binding liquid supply unit 30 to drive the binding liquid. Is supplied to the powder layer according to the cross-sectional data. By doing so, 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. 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 binding liquid is supplied from above to form a new cross-section. Form a member. 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, and the binding liquid supply unit 30, so that the cross-sectional members are layered one by one. Are formed and laminated.

  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 drive signals to the modeling unit 10, the powder layer forming unit 20, and the binding 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. 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. As the powder, it is possible to use powders of various materials such as resin, metal, and oxide, and it is also possible to use transparent powders, but in this embodiment, opaque powders are used. Yes. In addition, a suction pump 28 that sucks powder and partially removes the powder layer is mounted on the powder layer forming unit 20 of the present embodiment. 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 unit 16 is driven by an amount corresponding to the thickness of the powder layer to be formed, and the position of the bottom surface unit 14 is lowered downward (minus Y 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 speed of the powder is controlled to an appropriate supply speed according to the thickness of the powder layer to be formed and the moving speed of the powder layer forming unit 20. The rotation speed of the extension roller 26 is controlled to an appropriate rotation speed according to the moving speed of the powder layer forming unit 20. 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.

  Further, as shown in FIG. 1, a suction pump 28 is also mounted on the powder layer forming unit 20 of the present embodiment. The suction pump 28 includes a main body and a suction hose, and the tip of the suction hose is provided immediately above the powder layer formed by the extension roller 26. Further, the main body of the suction pump 28 can move only in the left-right direction (X direction) together with the powder layer forming unit 20, but the tip of the suction hose also moves in the direction perpendicular to the paper surface (Y direction). Is configured to be possible. Then, the powder layer formed by the extension roller 26 can be partially removed by moving the tip of the suction hose to suck the powder under the control of the control unit 44.

  The binding liquid supply unit 30 includes a binding liquid supply head 32 that supplies the binding liquid toward the powder layer, a binding liquid storage unit 34 that stores the binding liquid, and the like. In addition, a curable liquid supply head 36 for supplying a curable liquid, which will be described later, and a curable liquid storage section 38 for storing the curable liquid are also mounted on the binding liquid supply section 30 of the present embodiment. For the binding liquid supply head 32 and the curable liquid supply head 36 of this embodiment, a so-called piezo drive type liquid droplet ejection 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 binding liquid supply unit 30 of the present embodiment, the binding liquid stored in the binding liquid storage unit 34 is guided to the pressure chamber of the binding liquid supply head 32 to drive the piezo element, whereby the binding liquid is made into droplets. Can be discharged. Similarly, the curable liquid supply head 36 can discharge the curable liquid stored in the curable liquid storage portion 38 in the form of droplets.

  Here, a liquid resin material mainly composed of a monomer and an oligomer to which the monomer is bonded is used as the binding liquid. Further, a monomer having a comparatively low molecular weight is selected as the monomer of the binding liquid so that the viscosity can be discharged as droplets from the binding liquid supply head 32, and the number of molecules of monomers contained in one oligomer is further selected. Is adjusted to several molecules. And since the binding liquid is stable by itself, it can be ejected as droplets without being cured inside the binding liquid storage portion 34 or the binding liquid supply head 32, but when in contact with the polymerization initiator, The monomers are polymerized to each other to grow into oligomers, and the oligomers are also polymerized in various places and cured relatively quickly to become a solid. In the three-dimensional modeling apparatus 100 of the present embodiment, the surface of the powder is coated with a polymerization initiator, and when a droplet of the binding liquid is supplied to the powder layer, the binding liquid penetrates into the powder layer. It quickly cures in contact with the polymerization initiator on the powder surface. As a result, in the portion where the binding liquid is discharged, the powders are bonded by the cured binding liquid.

  On the other hand, a liquid mainly composed of a polymerization initiator and some solvent is used as the curable liquid. Therefore, when the curable liquid and the binding liquid are supplied simultaneously (or separately), the monomers and oligomers of the binding liquid start to be polymerized by the polymerization initiator contained in the curable liquid, and the binding liquid (precisely the binding liquid and The mixture with the curable liquid) can be cured.

  In addition, the binding liquid supply unit 30 is controlled by the control unit 44, independently of the powder layer forming unit 20, in the X direction (left-right direction on the paper surface of FIG. 1) and the Y direction (paper surface of FIG. 1). In the vertical direction).

B. Method for modeling a three-dimensional object of this embodiment:
The three-dimensional modeling apparatus 100 according to the present embodiment having the above-described configuration, when a transparent part is included in a part of a three-dimensional object to be modeled, allows the transparent part to have high transparency (or It can be formed with the correct refractive index). Below, the three-dimensional modeling apparatus 100 of a present Example demonstrates the method of modeling the three-dimensional object which has a transparent part.

  As described above with reference to FIG. 1, when modeling a three-dimensional object, it is necessary to store in advance the three-dimensional shape data of the object to be modeled. Then, cross-sectional data obtained by cutting the three-dimensional object into a plurality of cross sections is generated for each layer.

  FIG. 2 is an explanatory diagram conceptually showing how cross-section data for each cross-section is generated from the shape data of a three-dimensional object to be shaped. 2A conceptually shows the shape data of the three-dimensional object, and FIG. 2B conceptually shows the cross-sectional data obtained by cutting the three-dimensional object into layers. Yes. As shown in FIG. 2 (a), the three-dimensional object to be shaped has a tea tube shape with a slightly narrowed central portion, and a large round window is formed in the center of the upper and lower surfaces of the tea tube shape. Is formed. In the inside of the tea tube shape, a lens-shaped transparent portion is provided in a slightly narrowed portion at the center. Further, the portion other than the lens-shaped portion is opaque.

  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. 2B can be obtained. The intervals at which the cross sections are taken (in other words, the thicknesses of the respective layers) are not necessarily equal, but are assumed to be equal here. In FIG. 2B, in order to avoid the illustration from being complicated, the section is displayed with a thinned-out section as appropriate. As described above with reference to FIG. 2A, since the transparent portion is provided in the three-dimensional object, the transparent portion appears depending on the position where the cross section is taken. In FIG. 2 (b), the opaque portion of the cross-sectional data is represented by a fine oblique line, and the transparent portion is represented by a coarse oblique line. In this way, the cross-section data generation unit 42 of the present embodiment generates cross-section data for each cross-section from the shape data of the three-dimensional object, and supplies the generated cross-section data to the control unit 44 one layer at a time. Then, the control part 44 will form the cross section of a three-dimensional object one layer at a time in the modeling part 10 as follows, if cross-section data are received.

  FIG. 3 is an explanatory view conceptually showing a state in which a cross section of a three-dimensional object at a position not including a transparent portion (for example, the cross section position A shown in FIG. 2B) is formed according to cross section data. It is. At the cross-sectional position where the transparent portion is not included, the powder layer is formed by moving the powder layer forming unit 20 from the left to the right (plus X direction) on the paper surface. That is, the powder supply roller 24 is rotated to supply the powder in the hopper 22 at a constant speed, and the extension roller 26 is rotated in the direction opposite to the traveling direction so that excess powder is kicked forward. However, a powder layer is formed by stretching an appropriate amount of powder to a uniform thickness by the stretching roller 26. Further, at a location designated as an opaque part in the cross-sectional data, the cross-section of the three-dimensional object is formed by discharging the binding liquid from the binding liquid supply head 32 and bonding the powders of the powder layer to each other. In FIG. 3, portions where the binding liquid is discharged and the powders are bonded to each other are indicated by fine oblique lines.

  Whether or not to discharge the binding liquid from the binding liquid supply head 32 can be easily determined based on the cross-section data supplied from the cross-section data generation unit 42. For example, as illustrated in FIG. 3A, when the binding liquid supply head 32 is at a position where the cross section to be formed does not exist, the binding liquid is not discharged. Further, as illustrated in FIG. 3B, when the binding liquid supply head 32 is at a position where the cross section to be formed exists, the binding liquid is discharged toward the powder layer. Whether or not there is a cross section to be formed can be immediately determined based on the cross section data received from the cross section data generation unit 42. Further, as shown in FIG. 3B, when the binding liquid is discharged and the cross section is formed, a powder layer is formed, and when the binding liquid is discharged to the powder layer, the binding liquid is As it soaks in and reaches the previously formed cross-section and hardens, the newly formed cross-section is joined together with the lower cross-section. In this way, for a portion of the three-dimensional object that does not include a transparent portion, a powder layer is formed, and a bonding liquid is discharged according to the cross-sectional data, thereby laminating the cross-section in which the powders are bonded together. .

  On the other hand, when the transparent data is included in the cross-section data received from the cross-section data generator 42 (for example, in the case of the cross-section data at the cross-section position B shown in FIG. 2B), the following is performed. , Forming a cross section of a three-dimensional object.

  FIG. 4 is an explanatory diagram conceptually showing a state in which a cross section of a three-dimensional object at a position including a transparent portion is formed according to cross section data. Even when a cross-section including a transparent portion is formed, the powder layer is formed once by moving the powder layer forming unit 20 from the left to the right (plus X direction) on the paper surface. However, the powder layer is removed by sucking the powder using the suction pump 28 at the portion designated as the transparent portion in the cross-sectional data.

  FIG. 4A conceptually shows a state where the powder layer is removed by sucking the powder using the suction pump 28 after the powder layer is formed. Next, the curable liquid is discharged from the curable liquid supply head 36 to the portion from which the powder layer has been removed, and the binding liquid is discharged from the binding liquid supply head 32. FIG. 4B conceptually shows a state in which the curable liquid is discharged from the curable liquid supply head 36 and the binding liquid is discharged from the binding liquid supply head 32 to the portion from which the powder layer has been removed. Has been. As described above, since the curing liquid contains a polymerization initiator, the discharged bonding liquid is polymerized, and as a result, a transparent solid layer is formed by curing the mixture of the bonding liquid and the curing liquid. The In FIG. 4, the transparent portion formed by the binding liquid and the curable liquid without using the powder in this way is represented by rough diagonal lines. On the other hand, for the portion forming the opaque cross section, the cross section is formed by bonding the powders by discharging the binding liquid in the same manner as described with reference to FIG. In the case where the transparent data is included in the cross-sectional data received from the cross-sectional data generator 42, after removing the powder layer in the transparent part in this way, the curable liquid and the binding liquid are discharged to the part. The non-transparent part is formed by discharging the binding liquid and bonding the powder to form a cross section. By laminating the cross sections thus formed, it is possible to form a three-dimensional object without using powder in the transparent portion.

  Then, for all the cross-section data generated by the cross-section data generation unit 42, when the cross-section is formed and stacked, the modeled object is taken out from the powder layer stacked on the modeling unit 10. Then, since the powder that is not bonded by the binding liquid spills out, it is possible to obtain a three-dimensional object (for example, an object as shown in FIG. 3A) formed by stacking cross sections of powder. . Moreover, what is necessary is just to grind the surface as needed, when the surface of a transparent part is not smooth. The three-dimensional object obtained in this way is shaped using only the binding liquid and the hardening liquid without using powder in the transparent part, so that it is possible to ensure sufficient transparency and accurate refraction. Rate can be realized.

  Of course, as described above, powders of various materials can be used for the powder, and if a transparent powder is used, a transparent shaped article can be obtained. However, no matter how transparent powder is used or the combination of the powder and the binding liquid is adjusted, there is a limit to the transparency that can be achieved, and a molded object having an accurate refractive index can be obtained. Couldn't get. Hereinafter, the reason will be described.

  FIG. 5 is an explanatory view conceptually showing a state in which the powders are bound together by the binding liquid. Needless to say, since the powder forming the powder layer is solid and there is a gap between the powders, when the binding liquid is supplied to the powder layer, the binding liquid penetrates into the gap between the powders. Go. Then, when it comes into contact with the polymerization initiator previously applied to the surface of the powder, the binding liquid is polymerized and cured, and as a result, the powder is integrally bonded by the cured binding liquid. However, a boundary surface remains between the individual powders and the cured binding liquid. Further, in FIG. 5, the powder is shown as having a spherical shape, but naturally, the powder has a complicated surface shape instead of a spherical shape. For this reason, even if both the powder and the cured binding liquid are transparent, light is diffusely reflected at the boundary surface between the powder and the binding liquid, so that it becomes white and ensures high transparency. It is difficult. In addition, since light is irregularly reflected at the boundary surface, it is difficult to realize an accurate refractive index. In FIG. 5, the manner in which light is reflected at the boundary surface between the powder and the binding liquid is schematically represented by broken-line arrows.

  Of course, it is possible to make the boundary surface inconspicuous by adjusting the combination of the material of the powder and the binding liquid, thereby improving the transparency. However, it is impossible to completely eliminate the boundary surface, and in addition, since there are innumerable boundary surfaces inside the modeled object, there is a limit to improving the transparency. In addition, it is difficult to obtain an accurate refractive index as long as there are innumerable boundary surfaces inside.

  On the other hand, in the three-dimensional modeling apparatus 100 of the present embodiment, curing is performed by mixing the curing liquid and the binding liquid. Since both the curable liquid and the binding liquid are liquid, no clear boundary is generated, and therefore, light is not irregularly reflected inside the molded article. For this reason, it becomes possible to realize sufficient transparency that can be used as an optical component. Moreover, it becomes possible to give a desired refractive index to a molded article by appropriately selecting the binding liquid and, in some cases, the curing liquid.

C. Variation:
Various modifications exist in the three-dimensional modeling apparatus 100 of the present embodiment described above. Hereinafter, these modified examples will be briefly described.

C-1. First modification:
In the above-described embodiments, the powder layer is formed, the transparent portion of the powder layer is removed, and then the binding liquid or the curing liquid is discharged to form the cross section of the three-dimensional object. However, after forming the powder layer, before removing the powder layer in the transparent part, after discharging the binding liquid around the part to be removed and solidifying the powder, the powder layer in the transparent part is It may be removed.

  FIG. 6 shows a state in which a cross section including a transparent portion is formed by the method of the first modified example. Similar to FIG. 4 described above, a portion with a rough oblique line represents a transparent portion of the three-dimensional object, and a portion with a fine oblique line represents an opaque portion. Also in the first modification, first, the powder layer is formed while moving the powder layer forming unit 20 and the binding liquid supplying unit 30 in the positive X direction. However, before removing the powder layer in the transparent portion, the binding liquid is discharged to bind the powder in the opaque portion. At this time, the binding liquid is also discharged around the transparent portion to bond the powder. FIG. 6A shows a state in which a powder layer is formed while moving the powder layer forming unit 20 and the binding liquid supply unit 30 in the plus X direction, and the powder is bonded by discharging the binding liquid. Represents.

  After discharging the binding liquid and combining the powder layers, the powder layer forming unit 20 and the binding liquid supply unit 30 are moved in the negative X direction to return to the initial positions and then moved again in the positive X direction. . FIG. 6B shows a state in which the powder layer forming unit 20 and the binding solution supply unit 30 are moved again in the positive X direction on the powder layer that has been discharged and cured by the binding solution. Represents. When moving the second time, the suction pump 28 is operated to remove the powder layer of the transparent portion, and the portion from which the powder layer has been removed is transferred from the binding liquid supply head 32 and the curable liquid supply head 36. Each of the binding liquid and the curable liquid is discharged to form a transparent cured layer made of a mixture of the binding liquid and the curable liquid. 6C, the transparent powder layer is removed by the suction pump 28, and the binding liquid and the hardening liquid are discharged from the binding liquid supply head 32 and the hardening liquid supply head 36, so that the transparent hardening layer is formed. The state of formation is conceptually shown.

  In addition, when the powder layer forming unit 20 is moved after the powder layer is formed, it may be moved while rotating the extension roller 26 in the opposite direction to that at the time of forming the powder layer. For example, in FIG. 6A, since the powder roller is moving while being formed, the extension roller 26 is moved while being rotated in a direction opposite to the moving direction (counterclockwise in the drawing). When moving on the powder layer formed, as shown in FIG. 6B or FIG. 6C, the extension roller 26 is rotated in the moving direction and the forward direction (clockwise in the drawing). It may be moved while. At this time, the extension roller 26 may be freely rotated, or the moving speed of the powder layer forming unit 20 is set so that no speed difference is generated between the surface of the extension roller 26 and the powder layer. The extension roller 26 may be rotated according to the above. By doing so, there is no risk of roughening the surface of the powder layer that has already been formed by the extension roller 26, and conversely, the powder layer having a uniform thickness is obtained by re-adjusting with the extension roller 26. Is possible.

  Also by the method of the first modification as described above, the transparent portion of the three-dimensional object can be formed by curing the binding liquid and the curable liquid without using powder, so that the transparent portion is high. Transparency can be imparted, and an accurate refractive index can be imparted by appropriately selecting a binding liquid, a curing liquid, or the like. In addition, in the first modified example, since the powder layer is removed after the periphery of the transparent portion is cured with the binding liquid, the powder can be completely removed even near the contour of the transparent portion. As a result, high transparency can be secured over the entire range of the transparent portion, and an accurate refractive index can be imparted.

C-2. Second modification:
In the above-described embodiments, the bonding liquid that is polymerized by contact with the polymerization initiator has been described. However, it is also possible to use a bonding liquid mainly composed of a so-called photo-curing resin. In the following, a binding liquid mainly composed of a photo-curing resin is referred to as a photo-curing liquid. Similar to the above-described binding liquid, the photo-curing liquid is mainly composed of a monomer or an oligomer in which several monomers are polymerized, but the monomer or oligomer of the photo-curing liquid contains light of a specific wavelength (typically Polymerization starts when irradiated with (ultraviolet light). If a photo-curing liquid is used instead of the binding liquid, a transparent portion can be formed using the photo-curing liquid instead of the two kinds of liquids, that is, the binding liquid and the curing liquid.

  FIG. 7 is an explanatory diagram conceptually showing a state in which a three-dimensional object is formed by the second modification. In the second modification, the binding liquid supply head 32, the curable liquid supply head 36, the binding liquid storage part 34, and the curable liquid storage part 38 are not mounted, and instead, a photo curable liquid that discharges a photo curable liquid. A discharge head 33, a photo-curing liquid container 35 that contains a photo-curing liquid, and a light irradiation unit 50 that radiates ultraviolet light to cure the photo-curing liquid are mounted. Also in the second modification, when forming a cross section of a three-dimensional object, a powder layer is first formed. Then, the photocuring liquid is ejected from the photocuring liquid ejection head 33 to the opaque cross section. Then, since the discharged photocuring liquid permeates between the powders of the powder layer, the light curing unit 50 is irradiated with ultraviolet light using the light irradiation unit 50 to cure the photocuring liquid. Join bodies together. FIG. 7A conceptually shows a state in which the powder layer in the transparent portion is removed and a photo-curing liquid is discharged to the opaque portion and irradiated with ultraviolet light.

  Next, the photo-curing liquid discharge head 33 is moved to the portion from which the powder layer has been removed, the photo-curing liquid is discharged, and ultraviolet light is irradiated thereon to cure the photo-curing liquid. FIG. 7B conceptually shows a state in which a photo-curing liquid is discharged to a portion from which the powder layer has been removed to form a hardened layer using the photo-curing liquid. By doing so, it becomes possible to form the transparent portion of the three-dimensional object using only the photo-curing liquid. In addition, since the transparent part can be formed using only a single photo-curing liquid, it can be made more uniform and transparent than the transparent part formed by mixing the binding liquid and the curing liquid. It becomes. In addition, since only the photocuring liquid needs to be ejected, the mechanism for ejecting droplets can be simplified.

  Although the three-dimensional modeling apparatus 100 of the present embodiment has been described above, the present invention is not limited to all the embodiments described above, and can be implemented in various modes without departing from the spirit of the present invention.

  For example, in the above-described embodiments, the description has been given on the assumption that the transparent portion is provided inside the three-dimensional object. However, the transparent portion is not necessarily provided inside the object, for example, the surface of the object. A transparent portion may be provided. Even in such a case, if the object surface is formed without using powder, it can be formed more homogeneously and densely than using powder, so the surface has a fine finish. It is possible to form a three-dimensional object with a feeling.

It is explanatory drawing which showed the rough structure of the three-dimensional modeling apparatus of a present Example. It is explanatory drawing which showed a mode that the cross-sectional data in each cross-section were produced | generated from the shape data of the three-dimensional object to be modeled. It is explanatory drawing which showed a mode that the cross-section member in the position where the transparent part is not included was formed according to cross-section data. It is explanatory drawing which showed a mode that the cross-sectional member in the position where the transparent part was contained was formed according to cross-sectional data. It is explanatory drawing which showed a mode that powder was couple | bonded with the coupling | bonding liquid. It is explanatory drawing which showed a mode that the cross-sectional member containing a transparent part was formed by the method of a 1st modification. It is explanatory drawing which showed a mode that the cross-sectional member containing a transparent part was formed by the 2nd modification.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 ... Modeling part, 12 ... Frame, 14 ... Bottom face part, 16 ... Bottom face drive part,
20 ... powder layer forming part, 22 ... hopper, 24 ... powder supply roller,
26 ... Extension roller 28 ... Suction pump 30 ... Binding liquid supply unit,
32 ... Binding liquid supply head, 33 ... Photo-curing liquid discharge head,
34 ... Binding liquid storage part, 35 ... Photocuring liquid storage part, 36 ... Curing liquid supply head,
38 ... Curing liquid storage unit, 40 ... Calculation processing unit, 42 ... Cross section data generation unit,
44 ... Control unit, 50 ... Light irradiation unit, 100 ... Three-dimensional modeling apparatus

Claims (6)

A three-dimensional modeling apparatus that models a three-dimensional object by bonding powders together with a binding liquid,
Shape data storage means for storing shape data of a three-dimensional object having a transparent portion;
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;
The powder is spread to a substantially uniform thickness to form a powder layer, and the binding liquid is supplied to the powder layer according to the cross-sectional data, thereby corresponding to the cross-sectional shape of one layer of the three-dimensional object. Cross-sectional member forming means for forming a cross-sectional member to be
A new powder layer is formed on the powder layer on which the cross-sectional member is formed, and a new cross-sectional member is formed by supplying the binding liquid to the new powder layer according to the cross-sectional data. 3D object modeling means for modeling the 3D object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member,
The cross-section member forming means, when forming the cross-section member, for the portion determined to be transparent based on the cross-section data, instead of the powder layer, the binding liquid and a hardening liquid that cures the binding liquid Is a means for forming the cross-sectional member by curing the binding liquid. The three-dimensional modeling apparatus according to claim 1,
The cross-section member forming means, after forming the powder layer, removing the powder layer formed in a portion determined to be transparent based on the cross-sectional data, and then removing the binding liquid and the curing in the removed portion. A three-dimensional modeling apparatus which is means for forming the cross-sectional member by supplying a liquid. The three-dimensional modeling apparatus according to claim 2,
Prior to removing the portion of the powder layer determined to be transparent based on the cross-sectional data, the cross-section member forming means supplies the binding liquid around the portion to be removed, and then removes the powder layer. A three-dimensional modeling apparatus that is a means for removing. A three-dimensional modeling device that forms a three-dimensional object by supplying a light curable liquid that cures when irradiated with light to a modeled object by powder, and then irradiating light to bond the powders together. There,
Shape data storage means for storing shape data of a three-dimensional object having a transparent portion;
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;
The powder is spread to a substantially uniform thickness to form a powder layer, and the photo-curing liquid is supplied to the powder layer in accordance with the cross-sectional data, and then cured by irradiation with light, whereby the tertiary A cross-section member forming means for forming a cross-section member corresponding to the cross-sectional shape of one layer of the original object;
A new cross-sectional member is formed by forming a new powder layer on the powder layer on which the cross-sectional member is formed, supplying the photo-curing liquid to the new powder layer according to the cross-sectional data, and curing it. A three-dimensional object modeling means for modeling the three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member, and
The cross-section member forming means supplies the photo-curing liquid instead of the powder layer to the photo-curing liquid for the portion determined to be transparent based on the cross-section data when forming the cross-section member. A three-dimensional modeling apparatus, which is a means for forming the cross-sectional member by irradiating with light and curing. A three-dimensional modeling method for modeling a three-dimensional object by bonding powders together with a binding liquid,
A shape data storage step storing shape data of a three-dimensional object having a transparent portion;
A cross-section data generation step for generating cross-section data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections;
The powder is spread to a substantially uniform thickness to form a powder layer, and the binding liquid is supplied to the powder layer according to the cross-sectional data, thereby corresponding to the cross-sectional shape of one layer of the three-dimensional object. A cross-section member forming step for forming a cross-section member to be performed;
A new powder layer is formed on the powder layer on which the cross-sectional member is formed, and a new cross-sectional member is formed by supplying the binding liquid to the new powder layer according to the cross-sectional data. A three-dimensional object modeling step of modeling the three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member,
In the cross-section member forming step, when forming the cross-section member, for the portion determined to be transparent based on the cross-section data, instead of the powder layer, the binding liquid and a curable liquid for curing the binding liquid Is a step of forming the cross-sectional member by curing the binding liquid. A three-dimensional modeling method that forms a three-dimensional object by supplying a light curable liquid that cures when irradiated with light to a modeled object with powder, and then irradiating light to bond the powders together. There,
A shape data storage step storing shape data of a three-dimensional object having a transparent portion;
A cross-section data generation step for generating cross-section data obtained in each layer when the three-dimensional object is cut into layers in a plurality of cross sections;
The powder is spread to a substantially uniform thickness to form a powder layer, and the photo-curing liquid is supplied to the powder layer in accordance with the cross-sectional data, and then cured by irradiation with light, whereby the tertiary A cross-section member forming step of forming a cross-section member corresponding to the cross-sectional shape of one layer of the original object;
A new cross-sectional member is formed by forming a new powder layer on the powder layer on which the cross-sectional member is formed, supplying the photo-curing liquid to the new powder layer according to the cross-sectional data, and curing it. Forming a three-dimensional object by sequentially laminating the new cross-sectional member on the previously formed cross-sectional member, and forming a three-dimensional object,
In the cross-section member forming step, when forming the cross-section member, the photo-curing liquid is supplied instead of the powder layer for a portion determined to be transparent based on the cross-section data. A three-dimensional modeling method, which is a step of forming the cross-sectional member by irradiating light to light and curing.

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