Three-dimensional object manufacturing method, three-dimensional object, and shaping device

Patent metadata

Field	Value
Publication number	US-11718016-B2
Application number	US-201716080674-A
Country	US
Kind code	B2
Filing date	Feb 16, 2017
Priority date	Feb 29, 2016
Publication date	Aug 8, 2023
Grant date	Aug 8, 2023

Abstract

A three-dimensional object manufacturing method for manufacturing a three-dimensional object by ejecting a liquid shaping material and then solidifying the ejected shaping material includes: an interior forming process of forming an interior portion of the three-dimensional object by the shaping material; and a periphery forming process of forming a peripheral portion of a periphery of the interior portion by stacking a plurality of layers by the shaping material, where the shaping material for forming the interior portion in the interior forming process has a larger rigidity in a solid state compared to the shaping material for forming the peripheral portion in the periphery forming process, the periphery forming process is a process of forming a groove configuring one part of the peripheral portion, and the interior forming process is a process of forming the interior portion by placing the liquid shaping material in the groove.

First claim

The invention claimed is:

1. A three-dimensional object manufacturing method for manufacturing a three-dimensional object by ejecting shaping material in a liquid state and then solidifying the ejected shaping material, the method comprising:
an interior forming process of forming a portion of an interior of the three-dimensional object by a shaping material; and
a periphery forming process of forming a portion of a periphery of the portion of the interior by stacking a plurality of layers by a shaping material, wherein
the shaping material for forming the portion of the interior in the interior forming process has a larger rigidity in a solid state compared to the shaping material for forming the portion of the periphery in the periphery forming process,
the periphery forming process is a process of forming a groove configuring at least one part of the portion of the periphery, wherein the groove is formed by stacking the plurality of layers by the shaping material in a vertical direction orthogonal to an extending direction of the plurality of layers, and
the interior forming process is a process of forming the portion of the interior, after the groove is formed, by placing the shaping material in the liquid state in the groove formed by stacking of the plurality of layers before the portion of the periphery of one part of the three-dimensional object is formed in the periphery forming process,
wherein the interior forming process and the periphery forming process are processes of ejecting the shaping material in the liquid state through an inkjet method,
wherein the three dimensional object includes a first part and a second part that is narrower than the first part,
wherein the second part that is narrower than the first part is formed by the interior forming process and the periphery forming process.

2. The three-dimensional object manufacturing method as set forth in claim 1 , wherein a liquid used in the periphery forming process becomes the shaping material after solidifying.

3. The three-dimensional object manufacturing method as set forth in claim 1 , wherein the first part is formed by the interior forming process and the periphery forming process, and
the second part protrudes from the first part.

4. A three-dimensional object manufacturing method for manufacturing a three-dimensional object by ejecting a shaping material in a liquid state and then solidifying the ejected shaping material, the method comprising:
an interior forming process of forming a portion of an interior of the three-dimensional object with a reinforcement material other than the shaping material; and
a periphery forming process of forming a portion of a periphery of the portion of the interior by stacking a plurality of layers by the shaping material, wherein
the reinforcement material has a larger rigidity compared to the shaping material in a solid state,
wherein the periphery forming process is a process in which a direction orthogonal to an extending direction of the plurality of layers disposed by layering is a vertical direction,
wherein the reinforcement material has a planar shape extending in the extending direction of the plurality of layers and is disposed in plural positions in the vertical direction;
the three-dimensional object has a space formed at one part of an area on a lower side of each of the reinforcement material in the vertical direction in the periphery forming process,
the portion of the periphery includes a supporting portion that supports the reinforcement material on the lower side of the reinforcement material in the vertical direction in the periphery forming process and that configures one part of a boundary of the space.

5. The three-dimensional object manufacturing method as set forth in claim 4 , wherein the reinforcement material includes a connecting part for connecting with another member.

6. The three-dimensional object manufacturing method as set forth in claim 4 , wherein the interior forming process is a process in which the reinforcement material is disposed in the portion of the interior before the portion of the periphery of one part of the three-dimensional object is formed in the periphery forming process.

7. The three-dimensional object manufacturing method as set forth in claim 6 , wherein the periphery forming process is a process of ejecting the shaping material in the liquid state with a shaping device based on shaping data, and
the periphery forming process is a process of disposing the reinforcement material in the portion of the interior in the interior forming process, then detecting a position of the reinforcement material with respect to the portion of the periphery, and correcting the shaping data based on the detected position.

8. The three-dimensional object manufacturing method as set forth in claim 4 , wherein the interior forming process is a process in which the reinforcement material is inserted to the portion of the interior after all the portions of the periphery of the three-dimensional object are formed in the periphery forming process.

9. The three-dimensional object manufacturing method as set forth in claim 4 , wherein
a surface of the supporting portion of the surfaces forming the space is an inclined plane that does not overhang in the periphery forming process.

10. The three-dimensional object manufacturing method as set forth in claim 9 , wherein the supporting portion includes:
an end supporting part that supports the reinforcement material at an end of the reinforcement material in the extending direction of the plurality of layers; and
a non-end supporting part that supports the reinforcement material at a portion other than the end.

11. The three-dimensional object manufacturing method as set forth in claim 9 , wherein the reinforcement material has a hole formed at at least one part of an area having the space formed on both sides in a direction orthogonal to the extending direction of the plurality of layers.

12. A three-dimensional object manufacturing method for manufacturing a three-dimensional object by ejecting a shaping material in a liquid state and then solidifying the ejected shaping material, the method comprising:
an interior forming process of forming a portion of an interior of the three-dimensional object by the shaping material; and
a periphery forming process of forming a portion of a periphery of the portion of the interior by stacking a plurality of layers by the shaping material, wherein
the shaping material for forming the portion of the interior in the interior forming process has a larger rigidity in a solid state compared to the shaping material for forming the portion of the periphery in the periphery forming process,
the periphery forming process is a process of forming a groove configuring at least one part of the portion of the periphery, wherein the groove is formed by stacking the plurality of layers by the shaping material in a vertical direction orthogonal to an extending direction of the plurality of layers, and
the interior forming process is a process of forming the portion of the interior, after the groove is formed, by placing the shaping material in the liquid state in the groove formed by stacking of the plurality of layers after all the portions of the periphery of the three-dimensional object are formed in the periphery forming process,
wherein the interior forming process and the periphery forming process are processes of ejecting the shaping material in the liquid state through an inkjet method,
wherein the three dimensional object includes a first part and a second part that is narrower than the first part,
wherein the second part that is narr

Assignees

• Mimaki Eng Co Ltd

Inventors

• Ochi Kazuhiro
• Hakkaku Kunio
• Hara Hirofumi
• Kanai Nobuo
• Ohnishi Masaru

Classifications

• B29C64/112 Primary

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

• B24B27/0633

  using a cutting wire · CPC title

• B29C64/147

  using sheet material, e.g. laminated object manufacturing [LOM] or laminating sheet material precut to local cross sections of the 3D object · CPC title

• B29C64/241

  for rotary motion · CPC title

• B29C64/264

  Arrangements for irradiation · CPC title