Three-dimensional object and method for forming three-dimensional object

Patent metadata

Field	Value
Publication number	US-11247406-B2
Application number	US-201715788392-A
Country	US
Kind code	B2
Filing date	Oct 19, 2017
Priority date	Oct 21, 2016
Publication date	Feb 15, 2022
Grant date	Feb 15, 2022

Abstract

A three-dimensional object includes an outer-layer member and an inner structural member. The outer-layer member is a layer to constitute the surface of the three-dimensional object, and includes an inner space. The outer-layer member is made up of a plurality of divided outer-layer pieces formed of build material, which is functional ink ejected from a droplet ejection head and cured. The inner structural member is disposed in the inner space of the outer-layer member and configured to support the outer-layer member.

First claim

What is claimed is:

1. A method for forming a three-dimensional object, the method comprising:
forming an outer-layer member comprising a layer to constitute a surface of the three-dimensional object, and comprising an inner space, the outer-layer member comprising a plurality of divided outer-layer pieces, which are formed by ejecting functional ink from a droplet ejection head and curing the ejected functional ink;
forming an inner structural member disposed in the inner space of the outer-layer member and configured to support the outer-layer member; and
bonding the outer-layer member to an outer surface of the inner structural member so as to constitute the three-dimensional object,
wherein, in the forming the outer-layer member, the outer-layer member is formed by an ink-jet technology using coloring inks of a plurality of colors,
wherein, in the forming the inner structural member, the inner structural member is formed by curing a filament, and
wherein the method further comprises generating, based on formation data related to a shape of the three-dimensional object, outer-layer member formation data for forming the outer-layer member by forming the plurality of divided outer-layer pieces by the ink-jet technology, and inner structural member formation data for forming the inner structural member by curing the filament.

2. The method according to claim 1 , wherein
the outer surface of the inner structural member is elastically deformable or plastically deformable,
in the forming the inner structural member, a plurality of protrusions protruding from the outer surface are formed on the inner structural member, and
in the bonding the outer-layer member to the outer surface of the inner structural member, the plurality of protrusions are deformed when an inner surface of the plurality of divided outer-layer pieces comes into contact with the plurality of protrusions.

3. The method according to claim 1 , wherein
each of the plurality of divided outer-layer pieces includes at least one coupling portion to be coupled to another one of the plurality of divided outer-layer pieces, the coupling portion being formed along an edge portion of each of the plurality of divided outer-layer pieces, and having a concavo-convex shape such that the edge portion has a stepped cross-section.

4. A method for forming a three-dimensional object, the method comprising:
forming an outer-layer member comprising a layer to constitute a surface of the three-dimensional object, and comprising an inner space, the outer-layer member comprising a plurality of outer-layer pieces, which are divided by a cross-section and formed by ejecting functional ink from a droplet ejection head and curing the ejected functional ink; and
filling the inner space of the outer-layer member with filling material to constitute an inner structural member configured to support the outer-layer member so as to constitute the three-dimensional object, the inner space of the outer-layer member being filled with the filling material after the plurality of outer-layer pieces are assembled to form the outer-layer member comprising the inner space,
wherein, in the forming the outer-layer member, the outer-layer member is formed by a deposition forming method by an ink-jet using coloring inks of a plurality of colors,
wherein the method further comprises generating, based on formation data related to a shape of the three-dimensional object, outer-layer member formation data for forming the outer-layer member, and
wherein, in the generating the outer-layer member formation data, the outer-layer member formation data is generated such that a characteristic region becomes the cross-section, the characteristic region enabling a division line where the cross-sections are in contact with each other in the three-dimensional object to be inconspicuous.

5. The method according to claim 4 , wherein
each of the plurality of divided outer-layer pieces includes at least one coupling portion to be coupled to another one of the plurality of divided outer-layer pieces, the coupling portion being formed along an edge portion of each of the plurality of divided outer-layer pieces, and having a concavo-convex shape such that the edge portion has a stepped cross-section.

Assignees

• Mimaki Eng Co Ltd

Inventors

• Tanaka Yoshihiro
• Kobayashi Kosuke
• Furukawa Yoshikazu

Classifications

• B33Y80/00

  Products made by additive manufacturing · CPC title

• B29K2101/12

  Thermoplastic materials · CPC title

• B29C64/112

  using individual droplets, e.g. from jetting heads · CPC title

• B29C66/12841

  comprising at least two butt joint-segments · CPC title

• B29C66/532

  Joining single elements to the wall of tubular articles, hollow articles or bars · CPC title