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

Patent metadata

Field	Value
Publication number	US-2016297147-A1
Application number	US-201615086462-A
Country	US
Kind code	A1
Filing date	Mar 31, 2016
Priority date	Apr 10, 2015
Publication date	Oct 13, 2016
Grant date	—

Abstract

A method for manufacturing a three-dimensional object, the method comprises, a step of forming the three-dimensional object including a structure and a support body; a step of removing the support body from the three-dimensional object; wherein the step of forming the three-dimensional object comprising: a step of generating slice data of the three-dimensional object; a step of stacking a structural material constituting the structure and a support material constituting the support body based on the slice data; and the support material which is stacked based on the slice data has weakened parts dividing the support body into a plurality of parts.

First claim

What is claimed is:

1 . A method for manufacturing a three-dimensional object, the method comprising,
a step of forming the three-dimensional object including a structure and a support body; a step of removing the support body from the three-dimensional object; wherein the step of forming the three-dimensional object comprising:
a step of generating slice data of the three-dimensional object;
a step of stacking a structural material constituting the structure and a support material constituting the support body based on the slice data; and the support material which is stacked based on the slice data has weakened parts dividing the support body into a plurality of parts.

2 . The method for manufacturing a three-dimensional object according to claim 1 , wherein in the step of removing the support body from the three-dimensional object, the three-dimensional object is brought into contact with a solvent which dissolves the support material.

3 . The method for manufacturing a three-dimensional object according to claim 2 , wherein the weakened parts dissolves in a shorter time compared to the plurality of parts.

4 . The method for manufacturing a three-dimensional object according to claim 1 , wherein the weakened parts are continuously provided in a stacking direction of the support material.

5 . The method for manufacturing a three-dimensional object according to claim 4 , wherein the support body is formed to have a hanging beam structure including beams parallel to the stacking direction of the support material and beams perpendicular to the stacking direction of the support material, and strength of the weakened parts is lower than that of the plurality of parts.

6 . The method for manufacturing a three-dimensional object according to claim 5 , wherein the thickness of beams of the weakened parts perpendicular to the stacking direction of the support material is smaller than the thickness of beams of the plurality of parts.

7 . A three-dimensional shaping method for forming a three-dimensional object including a structure and a support body which supports the structure, by sequentially stacking a plurality of layers, the method includes:
a step of acquiring cross-section data representing a cross-section of the structure in a target layer; a step of determining whether or not a support required region where the support body is to be provided is required in the target layer, on the basis of the cross-section data of the structure in the target layer, and a shape of the structure formed after the target layer; and a generation step of, when it is determined that a support required region is required in the target layer, generating support body cross-section data representing a cross-section of a support body arranged in the support required region, and generating slice data of the target layer by adding the support body cross-section data of the support body to the cross-section data of the structure, and in order to divide the support body into a plurality of parts by weakened parts, support body cross-section data is generated in the generation step, the support body cross-section data including a cross-section part corresponding to the cross-section of the plurality of parts, and a cross-section part corresponding to the cross-section of the weakened parts.

8 . The three-dimensional shaping method according to claim 7 , wherein the weakened parts have a structure that is more readily dissolved in a solvent that dissolves the support body than the plurality of parts.

9 . The three-dimensional shaping method according to claim 7 , wherein the support body is formed in a hanging beam structure.

10 . The three-dimensional shaping method according to claim 9 , wherein the thickness of constituent members of the weakened parts which constitute the hanging beam structure is smaller than the thickness of constituent members of the plurality of parts which constitute the hanging beam structure.

11 . The three-dimensional shaping method according to claim 7 ,
wherein the structure has a hollow chamber having an opening, the support body is arranged inside the hollow chamber when the three-dimensional object is formed, and the size of the plurality of parts is smaller than the size of the opening.

12 . The three-dimensional shaping method according to claim 11 , wherein the opening is an exit hole which is provided in order to remove the support body present inside the hollow chamber after the three-dimensional object is formed.

13 . The three-dimensional shaping method according to claim 7 , further comprising a stack shaping step of sequentially forming and stacking respective layers made of a shaping material, on the basis of the generated slice data.

14 . A three-dimensional shaping system for forming a three-dimensional object including a structure and a support body which supports the structure, by sequentially stacking a plurality of layers,
the system comprising slice data generation means for generating slice data used in forming the layers, wherein the slice data generation means includes: acquisition means for acquiring cross-section data representing a cross-section of the structure in a target layer; determination means for determining whether or not a support required region where the support body is to be provided is required in the target layer, on the basis of the cross-section data of the structure in the target layer, and a shape of the structure formed after the target layer; and generation means for, when it is determined that a support required region is required in the target layer, generating support body cross-section data representing a cross-section of a support body arranged in the support required region, and generating slice data of the target layer by adding the support body cross-section data of the support body to the cross-section data of the structure, and in order to divide the support body into a plurality of parts by weakened parts, the generation means generates support body cross-section data which includes a cross-section part corresponding to the cross-section of the plurality of parts, and a cross-section part corresponding to the cross-section of the weakened parts.

15 . The three-dimensional shaping system according to claim 14 , further comprising an image forming unit which forms layers made of a shaping material, using the generated slice data.

16 . The three-dimensional shaping system according to claim 15 , wherein the image forming unit forms the layers made of the shaping material, using an electrophotographic system.

17 . The three-dimensional shaping system according to claim 14 , further comprising cleaning means for cleaning the formed three-dimensional object with a solvent which dissolves the support body.

Assignees

• Canon Kk

Inventors

• Osawa Hidefumi

Classifications

• B29C67/0092

  Operations & Transport · mapped topic

• B29L2022/00

  Hollow articles (tubular articles B29L2023/00; pneumatic tyres B29L2030/00) · CPC title

• B29C67/0088 Primary

  Operations & Transport · mapped topic

• B29C67/0096

  Operations & Transport · mapped topic

• B29C67/0074

  Operations & Transport · mapped topic