JP2024008192A - Three-dimensional object manufacturing method and program - Google Patents

Abstract

To provide a manufacturing method for forming a three-dimensional molding object having a good skin touch feeling surface by relaxing irregular rough feeling on the surface of the three-dimensional molding object formed of powder as a molding material, and to provide the three-dimensional molding object formed by the manufacturing method.SOLUTION: A manufacturing method for forming a three-dimensional molding object 10 according to the present invention includes the steps of: receiving three-dimensional data of the three-dimensional molding object 10; specifying a surface to be a surface of the three-dimensional molding object 10 in the received three-dimensional data; adding shape data for forming a predetermined pattern by repeatedly arranging three-dimensional shapes on the specified surface to the three-dimensional data; and forming the three-dimensional molding object 10 using the molding material based on the three-dimensional data to which the shape data is added.SELECTED DRAWING: Figure 4

Description

The present disclosure relates to a manufacturing method and program for forming a three-dimensional structure using powder as a modeling material.

In recent years, 3D printers that form three-dimensional objects (hereinafter also simply referred to as objects) using various methods have been developed. Specifically, three-dimensional manufacturing methods include, for example, material extrusion deposition method (FDM: Fused Deposition Modeling / FFF: Fused Filament Fabrication), powder sintering additive manufacturing method (SLS: Selective Laser Sintering / SLM: Selective Laser Melting), Examples include stereolithography (laser method/SLA: Stereo Lithography Apparatus).

Among various three-dimensional manufacturing methods, powder sintering additive manufacturing is a method that integrates multiple sintered layers by repeating the process of irradiating metal powder with a laser to form a sintered layer. This is a method of forming a shaped object, and is disclosed in Japanese Patent Application Laid-Open No. 2013-163829 (Patent Document 1). Modeled objects formed by powder sintering additive manufacturing have less anisotropy and are superior in strength. However, since the powder sintering additive manufacturing method has a slow manufacturing speed, there has been a problem in the cost of forming a shaped object. In order to solve this problem, instead of sintering the powder of the modeling material, a manufacturing method that increases the manufacturing speed by adding a melting accelerator to the powder and fusing it with heat (for example, Hewlett-Packard's HP Multi Jet Fusion) (registered trademark)) has been developed.

Japanese Patent Application Publication No. 2013-163829

Manufacturing methods that use powder as a modeling material to form three-dimensional objects, such as powder sintering additive manufacturing and modeling methods that add a melting accelerator to powder and fuse it with heat, are capable of producing anisotropic objects. It has the advantages of low strength and excellent strength. However, since the modeling material is a powder, there is a drawback that an irregular, rough texture remains on the surface of the formed object. Possible methods to improve this drawback include, for example, polishing the surface of the formed object or painting the surface of the formed object, but either method increases manufacturing costs. become. Furthermore, since 3D printers can freely form objects with complex shapes due to their characteristics, it is sometimes difficult to polish or paint the surfaces of the objects.

The present disclosure has been made in order to solve such problems, and provides a three-dimensional model that has a surface that is comfortable to the touch and alleviates the irregular roughness of the surface of a three-dimensional model formed using powder as a modeling material. The purpose of the present invention is to provide a manufacturing method and a program for forming objects.

A manufacturing method for forming a three-dimensional structure according to the present disclosure is a manufacturing method for forming a three-dimensional structure using powder as a modeling material. The manufacturing method includes a step of receiving three-dimensional data of a three-dimensional structure, and a step of identifying, in the received three-dimensional data, a surface of the three-dimensional structure that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged. a step of adding shape data for forming a predetermined pattern on the identified surface to the three-dimensional data; a step of forming a three-dimensional object using a modeling material based on the three-dimensional data to which the shape data has been added; including.

Another manufacturing method for forming a three-dimensional structure according to the present disclosure is a manufacturing method for forming a three-dimensional structure using powder as a modeling material. The manufacturing method includes a step of receiving 3D data of a 3D object, a step of forming the 3D object using a modeling material based on the received 3D data, and a step of forming the 3D object using the received 3D data. The method includes the steps of identifying, on the surface of an object, a surface on which a predetermined pattern in which three-dimensional shapes are repeatedly arranged is formed, and a step of forming a predetermined pattern on the identified surface.

The program of the present disclosure is a program executed by a processor that converts three-dimensional data received by a manufacturing device that forms a three-dimensional object using powdered modeling material. The program includes a step of receiving 3D data of a 3D object, and a step of identifying, in the received 3D data, a surface of the 3D object that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged. , adding shape data for forming a predetermined pattern on the identified surface to the three-dimensional data.

Another program of the present disclosure is a program executed by a processor that controls a manufacturing device that forms a three-dimensional structure using powdered modeling material. The program includes a step of receiving three-dimensional data of a three-dimensional structure, and a step of forming the three-dimensional structure using a modeling material based on the received three-dimensional data. The step of forming a three-dimensional object includes the steps of identifying, in the three-dimensional data, a surface of the three-dimensional object that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged, and a step of forming a predetermined pattern on the identified surface. forming.

The three-dimensional structure formed by the above manufacturing method has a surface that is soft to the touch, with less irregular roughness.

FIG. 1 is a schematic diagram of a three-dimensional structure according to an embodiment. FIG. 1 is a schematic diagram of a manufacturing apparatus for forming a three-dimensional structure according to an embodiment. It is a block diagram of the control part of the manufacturing device which forms a three-dimensional structure according to an embodiment. 3 is a flowchart illustrating a method of converting three-dimensional data input to a manufacturing apparatus for forming a three-dimensional structure according to an embodiment. FIG. 2 is a diagram for explaining a manufacturing method for forming a three-dimensional structure according to an embodiment. FIG. 3 is a diagram showing different three-dimensional shapes formed on the surface of a three-dimensional structure. It is a figure which shows the still different three-dimensional shape formed on the surface of a three-dimensional structure. It is a schematic diagram of a three-dimensional structure according to a modification. It is a figure for explaining the modification of the manufacturing method of forming a three-dimensional structure. It is a flowchart explaining the manufacturing method of forming the three-dimensional structure based on a modification.

Hereinafter, embodiments will be described in detail with reference to the drawings. In addition, the same reference numerals are attached to the same or corresponding parts in the drawings, and the description thereof will not be repeated.

[Three-dimensional object]
FIG. 1 is a schematic diagram of a three-dimensional structure 10 according to an embodiment. A three-dimensional structure 10 shown in FIG. 1 is a structure formed using a 3D printer using powder as a modeling material. The three-dimensional structure 10 has a rectangular parallelepiped shape for ease of explanation. However, since a 3D printer is originally capable of freely forming a complex-shaped object due to its characteristics, the shape of the three-dimensional object 10 is not limited to a rectangular parallelepiped. The modeling materials used include resin powders such as polypropylene and polyamide, and metal powders such as aluminum and iron.

The three-dimensional structure 10 is formed using powder as a modeling material, for example, by a powder sintering additive manufacturing method. Therefore, even if the surface 2 of the three-dimensional structure 10 is designed to be flat, an irregular rough texture remains due to the powder of the modeling material. Therefore, in the embodiment, a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is formed on the surface 2 of the three-dimensional structure 10. In the three-dimensional structure 10 shown in FIG. 1, a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is formed on all six surfaces 2. The predetermined pattern is, for example, a pattern in which three-dimensional shapes 2a are regularly and repeatedly arranged in a matrix, as shown in FIG.

By forming a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged on the surface 2 of the three-dimensional structure 10, the shape of the three-dimensional shapes 2a that are repeatedly arranged is better than the irregular unevenness caused by the powder of the modeling material. is the dominant feeling when touching the surface 2 with a human hand. Therefore, when a person touches the predetermined pattern formed on the surface 2 of the three-dimensional structure 10, the irregular roughness of the surface 2 of the three-dimensional structure 10 is alleviated, and the surface feels nice to the touch. felt. Here, in order for the predetermined pattern to become dominant as the feel of a person's hand when touching the surface 2 with a person's hand, for example, it is necessary to simultaneously touch two or more three-dimensional shapes 2a with a fingertip.

Specifically, it is known that the diameter of an average person's finger is about 13 mm to about 22 mm, based on the size of a ring. For example, if the diameter of the finger is 18 mm, the length of one side of the three-dimensional shape 2a needs to be 6 mm or less in order to include the two three-dimensional shapes 2a arranged repeatedly between them. That is, the length of one side of the three-dimensional shape 2a may be 1/3 or less of the diameter of the finger.

On the other hand, in a 3D printer that uses powder as a modeling material, the three-dimensional shape 2a cannot be formed in units smaller than the particle diameter of the modeling material, so the length of one side of the three-dimensional shape 2a only needs to be equal to or greater than the particle diameter of the modeling material. Here, the particle diameter of the modeling material may be an average particle diameter in volume distribution or number distribution, or may be a mode diameter, a median diameter, an arbitrary % particle diameter, or the like.

Specifically, the three-dimensional shape 2a shown in FIG. 1 is, for example, a cylindrical groove formed on the surface 2. When the average particle size (hereinafter also simply referred to as particle size) of the powder is about 50 μm, the three-dimensional shape 2a has a diameter of about 250 μm and a depth of about 250 μm. Here, the size of the three-dimensional shape 2a was set to five times the particle diameter of the modeling material, but if it is 1/3 or less of the diameter of a finger, the feeling when touching the surface 2 with a human hand is It is thought that the shape based on shape 2a is more dominant. For example, if the diameter of the finger is 22 mm, 1/3 of the finger diameter is about 7.3 mm, which is about 150 times the particle size of the modeling material. Considering the ease with which the three-dimensional shape 2a can be produced using a 3D printer using powder as a modeling material, the size of the three-dimensional shape is preferably from 5 times to 150 times the particle diameter of the modeling material.

The process of forming a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged on the surface 2 of the three-dimensional structure 10 is performed using the same modeling method (for example, powder This is done using sintering additive manufacturing method). Therefore, in order to form a predetermined pattern on the surface 2 of the three-dimensional structure 10, there is no need to polish or paint the surface 2, and the manufacturing cost does not increase. Moreover, since they are formed using the same modeling method, difficult work such as polishing or painting the surface after the three-dimensional structure 10 is completed does not occur.

The three-dimensional shape 2a is not limited to a cylindrical groove carved into the surface 2, but may instead be a cylindrical protrusion protruding from the surface 2. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2a, which are all cylindrical grooves, are lined up, or a pattern in which a plurality of three-dimensional shapes 2a, which are all cylindrical protrusions, are lined up. It may be a pattern in which a plurality of three-dimensional shapes 2a, which are grooves, and three-dimensional shapes 2a, which are cylindrical projections, are mixed and arranged.

[Manufacturing equipment for three-dimensional objects]
Next, a manufacturing apparatus for forming the three-dimensional structure 10 will be explained using the drawings. FIG. 2 is a schematic diagram of a manufacturing apparatus for forming a three-dimensional structure according to an embodiment. The manufacturing apparatus shown in FIG. 2 is an example of a powder sintering additive manufacturing apparatus.

The powder sintering additive manufacturing apparatus 50 includes a roller 3 (or blade) that supplies powder 20 of the modeling material to the modeling area 7, a laser light source 4 that sinters or melts the powder 20 placed in the modeling area 7 and joins the layers, It includes a galvanometer mirror 5 for moving the laser beam 6 at high speed in the modeling region 7. Further, the powder sintering additive manufacturing apparatus 50 includes a control unit 30 that converts the three-dimensional data of the received three-dimensional structure, controls the roller 3, the laser light source 4, and the like.

The powder sintering additive manufacturing apparatus 50 also includes a modeling area 7 for printing the three-dimensional object 10, a container 8 having a storage area for storing the powder 20 disposed on both sides of the printing area 7, and a container 8 for storing the powder 20 in the printing area 7. It includes a piston 11 for vertically moving the powder 20, and a piston 12 for vertically moving the powder 20 in the storage area. Although not shown, the powder sintering layered manufacturing apparatus 50 includes a heater, and the heater maintains the modeling area 7 and the storage area at a high temperature. Note that the temperature of the storage area where the powder 20 is stored is preferably lower than the temperature of the modeling area 7.

In the powder sintering additive manufacturing apparatus 50, first, the powder 20 in the storage area is spread over the modeling area 7 using the roller 3, the powder 20 is sintered or melted with the laser beam 6, and this process is repeated to create three-dimensional modeling. Object 10 is formed. The layered thickness of the powder 20 spread out by the roller 3 is set to several hundreds of micrometers or less to the extent that thermal decomposition does not occur.

In the powder sintering layered manufacturing apparatus 50, as a result of repeatedly performing the above processing, the three-dimensional structure 10 is buried in the powder 20. After taking out the three-dimensional structure 10 from the powder 20, the three-dimensional structure 10 is completed by peeling the powder 20 from the three-dimensional structure 10 by blasting or the like.

In the powder sintering additive manufacturing apparatus 50, the three-dimensional object 10 is modeled using 3D CAD in the control unit 30 within the apparatus or a computer connected via a network, and based on the model, the irradiation conditions for laser irradiation ( For example, processing procedures such as laser power, laser scanning speed, laser pitch, irradiation direction, and number of irradiations are set.

This processing procedure also includes forming a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional structure 10. The designer of the 3D object 10 automatically processes the 3D data of the 3D object 10 received by the powder sintering additive manufacturing apparatus 50 without being aware of the surface processing procedure of the 3D object 10. Then, the surface of the three-dimensional structure 10 is converted into three-dimensional data of the three-dimensional structure 10 with a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged. Of course, if the designer determines that it is not necessary to form a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional model 10, the powder sintering layered manufacturing apparatus 50 You can set it so that the original data is not converted.

FIG. 3 is a block diagram of a control unit of a manufacturing apparatus for forming a three-dimensional structure according to an embodiment. A program executed by the control unit 30 allows the received three-dimensional data of the three-dimensional structure 10 to be used to create a three-dimensional structure 10 in which a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional structure 10 is formed. Converted to three-dimensional data. It includes a control section 30, a processor 302, a main memory 304, an input section 306, an output section 308, a storage 310, an external drive 312, and a communication controller 320. These components are connected via processor bus 318.

The processor 302 is configured with a CPU, a GPU, or the like, and can read programs (for example, the OS 3102 and the program 3104) stored in the storage 310, expand them to the main memory 304, and execute them. The processor 302 executes a program 3104 that performs data conversion on the three-dimensional data of the three-dimensional structure 10 received by the input unit 306.

The main memory 304 is composed of a volatile storage device such as DRAM or SRAM. The storage 310 is composed of, for example, a nonvolatile storage device such as an HDD or an SSD.

In addition to the OS 3102 for realizing basic functions, the storage 310 stores a program 3104 for converting data, and the like. That is, the program 3104 converts the received three-dimensional data of the three-dimensional structure 10 into three-dimensional data of the three-dimensional structure 10 in which a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional structure 10 is formed. Convert.

The input unit 306 includes a keyboard, a mouse, and the like, and can further receive operations from the user. The input unit 306 can input, for example, information on the average particle diameter of the powder to be used, information selected by the user based on the results of trial production several times while changing the size of the three-dimensional shape 2a in a plurality of patterns, and the like. The output unit 308 outputs control signals for controlling the roller 3, laser light source 4, etc. based on the converted three-dimensional data. Further, the output unit 308 outputs the converted three-dimensional data, the shape of the three-dimensional shape 2a, the pattern, etc. to a display connected to the powder sintering additive manufacturing apparatus 50, etc.

The user performs trial production several times by changing the size and shape of the three-dimensional shape 2a of the pattern to be formed on the surface of the three-dimensional object 10, evaluates the feel, etc., and selects the optimal pattern by powder sintering and additive manufacturing. The selection can be made on the device 50. In addition, the user can preset a pattern in the powder sintering additive manufacturing apparatus 50 in which the unevenness due to the formed pattern is more dominant in terms of tactile sensation than the random unevenness due to the particles of the powder used. It is possible to set various sizes and shapes of the three-dimensional shape 2a from among the patterns created.

The control unit 30 has an external drive 312, which stores data from a recording medium (for example, an optical recording medium such as a DVD (Digital Versatile Disc), a USB memory) in which a computer-readable program is stored. The program may be read and installed in the storage 310 or the like. The communication controller 320 exchanges signals with other devices using wired or wireless communication. The powder sintering additive manufacturing apparatus 50 may exchange data with a data server or the like via the communication controller 320.

The program 3104 and the like executed by the control unit 30 may be installed via a computer-readable recording medium, or may be installed by downloading from a server device on a network. Further, the functions provided by the control unit 30 may be realized by using part of the modules provided by the OS.

Next, the three-dimensional data of the three-dimensional model 10 received by the powder sintering additive manufacturing apparatus 50 is automatically added to a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional model 10. The process of converting the original object 10 into three-dimensional data will be described in detail. FIG. 4 is a flowchart illustrating a method for converting three-dimensional data input to a manufacturing apparatus for forming a three-dimensional object according to the embodiment. First, the control unit 30 receives three-dimensional data of the three-dimensional structure 10 (step S101).

Next, the control unit 30 receives input information such as information on the average particle diameter of the powder to be used and information selected by the user based on the results of several trial productions while changing the size of the three-dimensional shape 2a in a plurality of patterns. (Step S102). In addition, the control unit 30 can select the size of the three-dimensional shape 2a of the user's preference by inputting the information selected by the user. It is possible to set various patterns and sizes of the three-dimensional shape 2a in which a predetermined pattern becomes dominant as a feel of the human hand. Further, the control unit 30 only needs to be able to determine the pattern based on at least one of information on the particle diameter of the modeling material and information on the three-dimensional shape 2a selected by the user.

When the information on the particle size, the information selected by the user, etc. is received (YES in step S102), the control unit 30 determines a pattern to be formed on the surface of the three-dimensional structure 10 based on the received information (step S103). ). If particle size information, information selected by the user, etc. is not received (NO in step S102), the control unit 30 returns the process to step S102 and waits for information to be input. Of course, the control unit 30 may set the pattern formed on the surface of the three-dimensional structure 10 as the default pattern if the particle size information, user-selected information, etc. are not input for a predetermined period of time.

Next, the control unit 30 specifies, in the received three-dimensional data, a surface on the surface 2 of the three-dimensional structure 10 that forms a pattern in which the three-dimensional shapes 2a are repeatedly arranged (step S104). The surface to be identified in step S104 may be automatically identified from the three-dimensional data received by the control unit 30, or may be manually identified by the user by displaying the received three-dimensional data on a display or the like. Further, the surfaces specified in step S104 may be all surfaces of the front surface 2 of the three-dimensional structure 10, or may be surfaces other than the surfaces that come into contact with other three-dimensional structures (surfaces that will become the surfaces of the final product). Of course, even if it is a surface that will become the surface of the final product, if a pattern in which the three-dimensional shapes 2a are repeatedly arranged is not formed, giving priority to design, the surface does not need to be specified in step S104. It should be noted that the user manually specifies the surface on which a pattern in which the three-dimensional shapes 2a are repeatedly arranged is not formed, giving priority to design.

The control unit 30 converts the shape data in which the three-dimensional shapes 2a are repeatedly arranged in the determined pattern on the specified surface into three-dimensional data (step S105). The control unit 30 converts and outputs the three-dimensional data to the powder sintering additive manufacturing apparatus 50 (step S104). The powder sintering additive manufacturing apparatus 50 forms a three-dimensional structure 10 in which a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is formed on the surface 2 based on the converted three-dimensional data.

[Method for manufacturing three-dimensional objects]
Next, a manufacturing method for forming the three-dimensional structure 10 will be explained using the drawings. FIG. 5 is a diagram for explaining a manufacturing method for forming the three-dimensional structure 10 according to the embodiment. In FIG. 5, a manufacturing method for forming a three-dimensional structure 10 using a powder sintering additive manufacturing method will be described.

First, as shown in FIG. 5(a), the powder 20 is placed in the modeling area using the roller 3. Next, as shown in FIG. 5(b), in order to form a portion that will become the surface of the three-dimensional structure 10, a pattern is formed in which three-dimensional shapes 2a, which are cylindrical projections, are regularly and repeatedly arranged. Specifically, the galvanometer mirror 5 is driven so as to irradiate the laser beam 6 onto the powder 20 in the portion forming the three-dimensional shape 2a, and the portion of the powder 20 irradiated with the laser beam 6 is sintered.

Furthermore, as shown in FIG. 5(c), the powder 20 is placed with the roller 3 in the modeling area where a part of the three-dimensional shape 2a is formed. By placing the powder 20 in the modeling area with the roller 3 and repeating the process of irradiating the powder 20 with the laser beam 6 and sintering the powder 20, the three-dimensional shape 2a is formed, and further, as shown in FIG. 5(d), A part of the three-dimensional structure 10 is formed.

Further, as shown in FIG. 5(e), the powder 20 is placed with the roller 3 in the modeling area where a part of the three-dimensional structure 10 is formed. By repeating the process of setting the powder 20 in the modeling area with the roller 3 and sintering the powder 20 by irradiating the laser beam 6, the three-dimensional structure 10 is completed as shown in FIG. 5(f).

[Surface pattern]
It has been explained that in the three-dimensional structure 10 shown in FIG. 1, a predetermined pattern in which three-dimensional shapes 2a, which are cylindrical grooves, are repeatedly arranged is formed on the surface 2. However, the three-dimensional shape formed on the surface of the three-dimensional structure 10 is not limited to a cylindrical groove. FIG. 6 is a diagram showing different three-dimensional shapes formed on the surface of the three-dimensional structure 10.

The pattern shown in FIG. 6A is a pattern in which three-dimensional shapes 2b, which are triangular prism-shaped grooves, are regularly and repeatedly arranged in a matrix. Specifically, the size of the three-dimensional shape 2b shown in FIG. 6(a) is, for example, when the powder particles are about 50 μm, the length of one side is about 250 μm, and the depth is about 250 μm.

The three-dimensional shape 2b is not limited to a triangular prism-shaped groove carved on the surface 2, but may instead be a triangular prism-shaped protrusion protruding from the surface 2. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2b, which are all triangular prism-shaped grooves, are lined up, or a pattern in which a plurality of three-dimensional shapes 2b, which are all triangular prism-shaped protrusions, are lined up. It may be a pattern in which a plurality of three-dimensional shapes 2b, which are grooves, and three-dimensional shapes 2b, which are triangular prism-shaped protrusions, are mixed and arranged.

The pattern shown in FIG. 6(b) is a pattern in which three-dimensional shapes 2c, which are grooves in which a part of a cube is embedded, are regularly and repeatedly arranged in a matrix. Specifically, the size of the three-dimensional shape 2c shown in FIG. 6(b) is, for example, when the powder particles are about 50 μm, the length of one side is about 250 μm.

The three-dimensional shape 2c is not limited to a groove carved into the surface 2, but may instead be a protrusion such as a part of a cube protruding from the surface 2. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2c, which are all grooves, are lined up, or a pattern in which a plurality of three-dimensional shapes 2c, which are all protrusions, are lined up. It may be a pattern in which a plurality of certain three-dimensional shapes 2c are mixed and arranged.

The shapes of the three-dimensional shapes 2a to 2c described above are examples, and the present invention is not limited to these shapes. Further, the predetermined pattern formed on the surface 2 of the three-dimensional structure 10 is not limited to a pattern in which three-dimensional shapes are regularly and repeatedly arranged in a matrix, for example, three-dimensional shapes are regularly arranged in one direction. Although a plurality of three-dimensional shapes are arranged side by side, a plurality of three-dimensional shapes may be arranged irregularly in other directions. Further, the predetermined pattern formed on the surface 2 of the three-dimensional structure 10 may be a pattern in which a plurality of three-dimensional shapes are arranged in a certain pattern and the pattern is repeated. A pattern in which three-dimensional shapes are repeatedly arranged is more dominant in terms of the feel when the surface 2 of the three-dimensional object 10 is touched by a human hand than the irregular irregularities caused by the powder of the modeling material. If so, the predetermined pattern may be any pattern.

The three-dimensional shape formed on the surface of the three-dimensional structure is not limited to one type, and may be a plurality of different three-dimensional shapes. For example, as in the pattern shown in FIG. 6(c), the three-dimensional shapes are three-dimensional shape 2a (first three-dimensional shape) which is a cylindrical groove and three-dimensional shape 2b (second three-dimensional shape) which is a triangular prism groove. ) may have two different shapes. The predetermined pattern formed on the surface of the three-dimensional structure is formed by regularly forming a three-dimensional shape 2a (first three-dimensional shape) which is a cylindrical groove and a three-dimensional shape 2b (second three-dimensional shape) which is a triangular prism groove. It may also be a pattern that is repeated.

FIG. 7 is a diagram showing still another three-dimensional shape formed on the surface of the three-dimensional structure. The pattern shown in FIG. 7A is a pattern in which ridges 2d connected diagonally in the figure are regularly and repeatedly arranged. Specifically, the size of the ridge 2d (three-dimensional shape) shown in FIG. 7(a) is, for example, when the powder particles are about 50 μm, the depth is about 250 μm.

The ridge 2d is not limited to a shape that protrudes from the surface 2 and slopes gently to the next ridge 2d, but may instead be a cliff formed by carving the surface 2. Moreover, the direction in which the ridges 2d are continuous is not limited to the direction shown in FIG. 7(a), and may be in another direction.

The pattern shown in FIG. 7(b) is a pattern in which three-dimensional shapes 2e, which are hexagonal columnar grooves, are regularly and repeatedly arranged in a honeycomb shape. Specifically, the size of the three-dimensional shape 2e shown in FIG. 7(b) is, for example, when the powder particles are about 50 μm, the length of one side is about 250 μm, and the depth is about 250 μm.

The three-dimensional shape 2e is not limited to a hexagonal columnar groove carved on the surface 2, but may instead be a hexagonal columnar protrusion protruding from the surface 2. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2e, which are all hexagonal columnar grooves, are lined up, or a pattern in which a plurality of three-dimensional shapes 2e, which are all hexagonal columnar protrusions, are lined up. It may be a pattern in which a plurality of three-dimensional shapes 2e, which are grooves, and three-dimensional shapes 2e, which are hexagonal columnar projections, are mixed and arranged.

The pattern shown in FIG. 7(c) is a pattern in which three-dimensional shapes 2f, which are columnar grooves extending in three directions, are regularly and repeatedly arranged. Specifically, the size of the three-dimensional shape 2f shown in FIG. 7(c) is, for example, when the powder particles are about 50 μm, the length of one side is about 250 μm, and the depth is about 250 μm.

The three-dimensional shape 2f is not limited to a columnar groove extending in three directions as if carved on the surface 2, but may instead be a columnar protrusion protruding from the surface 2. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2f, all of which are columnar grooves extending in three directions, are lined up, or a pattern in which a plurality of three-dimensional shapes 2f, all of which are columnar projections, are lined up. It may be a pattern in which a plurality of three-dimensional shapes 2f, which are columnar grooves that spread in the direction, and three-dimensional shapes 2f, which are protrusions, are mixed and arranged.

[Modified example]
In the three-dimensional structure 10 shown in FIG. 1, a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is formed on all six surfaces 2. However, it is not necessary to form a predetermined pattern on all six surfaces 2. FIG. 8 is a schematic diagram of a three-dimensional structure 10a according to a modification. In the three-dimensional structure 10a shown in FIG. 8, a predetermined pattern in which three-dimensional shapes 2g, which are grooves, are repeatedly arranged is formed on the top surface at the upper side of the figure and the bottom surface (not shown) at the lower side of the figure. A predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is formed on the surface. The three-dimensional shape 2g is a groove extending in one direction, and the size of the groove is, when the powder particles are about 50 μm, the width is about 250 μm, the depth is about 250 μm, and the distance to the next groove is about 250 μm. It is.

Note that the three-dimensional shape 2g is not limited to a groove carved into the surface 2, but may instead be a protrusion that protrudes from the surface 2 and extends in one direction. Furthermore, the pattern formed on the surface 2 may be a pattern in which a plurality of three-dimensional shapes 2g that are all grooves are lined up, or a pattern in which a plurality of three-dimensional shapes 2g that are all protrusions are lined up, or a pattern that is formed by a three-dimensional shape 2g that is a groove and a protrusion. It may be a pattern in which a plurality of certain three-dimensional shapes 2g are mixed and arranged.

FIG. 8 shows a three-dimensional structure 10a in which two of the six surfaces, the top surface and the bottom surface, have a pattern different from the pattern on the other surfaces. Therefore, the two surfaces, the top surface and the bottom surface, have a different feel from the other surfaces. Further, it is possible to add a function such as making the two surfaces, the top surface and the bottom surface, more slippery in one direction than the other surface. It should be noted that the three-dimensional structure may be a three-dimensional structure in which different patterns are formed on all six sides, or a three-dimensional structure in which a different pattern is formed on one of the six sides. Of course, among the six sides of the three-dimensional structure, there may be a side on which a predetermined pattern in which a plurality of three-dimensional shapes are arranged is not formed.

Next, a manufacturing method different from the manufacturing method of forming the three-dimensional structure 10 using the powder sintering additive manufacturing method explained in FIG. 5 will be described. FIG. 9 is a diagram for explaining a modification of the manufacturing method for forming a three-dimensional structure. In Figure 9, a manufacturing method is explained in which a three-dimensional model with a predetermined pattern formed on the surface 2 is formed by adding a melting accelerator to the powder and fusing it with heat instead of sintering the powder of the modeling material. do.

In FIG. 9(a), after the three-dimensional structure 10 has already been formed by the manufacturing method up to its upper surface, a predetermined pattern in which three-dimensional shapes 2a are repeatedly arranged is then formed on the surface of the three-dimensional structure 10. It shows the process of forming. First, the powder 20 is placed in a modeling area including the surface of the three-dimensional structure 10 using a roller (not shown). Next, as shown in FIG. 9(b), the head 9 that sprays the dissolution promoter 9a and the surface decoration agent 9b at high speed is scanned, and the dissolution promoter is applied to the powder 20 in the portion forming the three-dimensional shape 2a. 9a, and the surface decoration agent 9b is sprayed onto the powder 20 in other parts.

In FIG. 9(c), the hatched portion of the powder 20 indicates the portion of the powder 20 onto which the dissolution promoter 9a has been injected. Further, heat is applied by a heater 15 (for example, a halogen lamp) to the part of the powder 20 onto which the dissolution promoter 9a has been sprayed, thereby melting the powder 20. Here, the powder 20 is made of thermoplastic resin. Note that the heater 15 controls the heating temperature based on the measurement result from a temperature sensor that measures the temperature of the surface of the molded object. Through this control, a fine shape of a three-dimensional structure can be formed.

As shown in FIG. 9D, a plurality of three-dimensional shapes 2a are formed on the surface of the three-dimensional structure 10, and a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged is formed on the surface of the three-dimensional structure 10. Thereafter, the powder 20 is peeled off from the three-dimensional structure by blasting or the like, thereby completing the three-dimensional structure. Regarding the modeling methods for forming three-dimensional objects, we have explained the powder sintering additive manufacturing method and the modeling method in which a melt accelerator is added to the modeling material and heated, but three-dimensional objects are formed using powder as the building material. Any modeling method may be used as long as it is a modeling method.

In the embodiment described above, the powder sintering additive manufacturing apparatus 50 automatically creates a predetermined pattern in which the three-dimensional shapes 2a are repeatedly arranged on the surface of the three-dimensional structure 10 based on the three-dimensional data of the three-dimensional structure 10 received. It has been explained that the data is converted into three-dimensional data of the three-dimensional structure 10 to which the three-dimensional object 10 is added. However, the powder sintering additive manufacturing apparatus 50 does not convert the three-dimensional data, and when forming the three-dimensional object 10 based on the received three-dimensional data, the three-dimensional shape It is also possible to specify a surface on which a predetermined pattern is formed by repeatedly arranging 2a, and to form the predetermined pattern by adding the predetermined pattern to the specified surface. Specifically, when forming the three-dimensional structure 10, a manufacturing method in which a predetermined pattern is added and formed on the surface of the three-dimensional structure 10 will be described. FIG. 10 is a flowchart illustrating a manufacturing method for forming a three-dimensional structure according to a modification. First, the control unit 30 receives three-dimensional data of the three-dimensional structure 10 (step S201).

Next, the control unit 30 receives input information such as information on the average particle diameter of the powder to be used and information selected by the user based on the results of several trial productions while changing the size of the three-dimensional shape 2a in a plurality of patterns. (Step S202). In addition, the control unit 30 can select the size of the three-dimensional shape 2a of the user's preference by inputting the information selected by the user. It is possible to set various patterns and sizes of the three-dimensional shape 2a in which a predetermined pattern becomes dominant as a feel of the human hand.

When the information on the particle size, the information selected by the user, etc. is received (YES in step S202), the control unit 30 determines a pattern to be formed on the surface of the three-dimensional structure 10 based on the received information (step S203). ). If particle size information, information selected by the user, etc. is not received (NO in step S202), the control unit 30 returns the process to step S102 and waits for information to be input. Of course, the control unit 30 may set the pattern formed on the surface of the three-dimensional structure 10 as the default pattern if the particle size information, user-selected information, etc. are not input for a predetermined period of time.

Next, when forming the three-dimensional structure 10 based on the received three-dimensional data, the control unit 30 determines whether the part to be formed is the surface of the three-dimensional structure 10 (step S204). If the part to be formed is not the surface of the three-dimensional structure 10 (NO in step S204), the control unit 30 forms the three-dimensional structure 10 based on the three-dimensional data (step S205).

If the part to be formed is the surface of the three-dimensional structure 10 (YES in step S204), the control unit 30 forms a shape in which the three-dimensional shapes 2a are repeatedly arranged in the determined pattern on the surface of the three-dimensional structure 10 ( Step S206). The control unit 30 determines whether it is okay to form all three-dimensional objects 10 based on the received three-dimensional data and end the forming process (step S207). If it is not determined that the forming process can be ended (NO in step S207), the control unit 30 returns the process to step S204 and continues the forming process of the three-dimensional structure 10. On the other hand, if it is determined that the forming process may be ended (YES in step S207), the control unit 30 ends the forming process of the three-dimensional structure 10.

[Mode]
It will be understood by those skilled in the art that the embodiments described above are specific examples of the following aspects.

(Section 1)
A manufacturing method for forming a three-dimensional structure according to one embodiment is a manufacturing method for forming a three-dimensional structure using powder as a modeling material, and includes a step of receiving three-dimensional data of the three-dimensional structure, and a step of receiving three-dimensional data of the three-dimensional structure; A process of identifying a surface of the three-dimensional object in the data that forms a predetermined pattern of repeating three-dimensional shapes, and a process of adding shape data that forms a predetermined pattern on the identified surface to the three-dimensional data. and a step of forming a three-dimensional object using a modeling material based on the three-dimensional data to which shape data has been added.

According to the manufacturing method for forming a three-dimensional structure described in item 1, a predetermined pattern in which three-dimensional shapes are repeatedly arranged on the surface is formed, so the irregular roughness of the surface is alleviated and the texture is pleasant to the touch. A three-dimensional structure having a surface can be formed. Further, according to the manufacturing method, since the three-dimensional structure is integrally formed with a predetermined pattern in which three-dimensional shapes are repeatedly arranged on the surface, the manufacturing cost does not increase and difficult work is not required.

(Section 2)
A manufacturing method for forming a three-dimensional structure according to another aspect is a manufacturing method for forming a three-dimensional structure using powder as a modeling material, which includes a step of receiving three-dimensional data of the three-dimensional structure; A process of forming a three-dimensional object using modeling materials based on three-dimensional data, and a process of forming a predetermined pattern of repeating three-dimensional shapes on the surface of the three-dimensional object based on the received three-dimensional data. The method includes a step of specifying, and a step of forming a predetermined pattern on the specified surface.

According to the manufacturing method for forming a three-dimensional structure described in item 1, a predetermined pattern in which three-dimensional shapes are repeatedly arranged on the surface is formed, so the irregular roughness of the surface is alleviated and the texture is pleasant to the touch. A three-dimensional structure having a surface can be formed. Furthermore, according to the manufacturing method, the process of forming a three-dimensional object and the process of forming a predetermined pattern in which three-dimensional shapes are repeatedly arranged are performed using the same modeling method, so that the manufacturing cost does not increase. Do not create difficult tasks.

(Section 3)
The manufacturing method for forming a three-dimensional structure according to item 1 or 2, wherein the length of one side of the three-dimensional shape is greater than or equal to the particle diameter of the modeling material and less than or equal to 1/3 of the diameter of a finger. .

According to the manufacturing method for forming a three-dimensional structure described in item 3, the length of one side of the three-dimensional shape is greater than or equal to the particle diameter of the modeling material and less than or equal to 1/3 of the diameter of the finger. The irregular roughness is alleviated, and the surface of the three-dimensional object can be formed with a pleasant texture.

(Section 4)
A manufacturing method for forming a three-dimensional structure according to any one of Items 1 to 3, wherein at least one of information on the particle size of the modeling material and information on the three-dimensional shape selected by the user is provided. The method further includes determining a predetermined pattern based on the information.

According to the manufacturing method for forming a three-dimensional structure described in Section 4, the three-dimensional structure is The three-dimensional pattern to be formed on the surface of the object can be determined.

(Section 5)
In the manufacturing method for forming a three-dimensional structure according to any one of Items 1 to 4, the predetermined pattern is a pattern in which three-dimensional shapes having the same shape are repeatedly arranged.

According to the manufacturing method for forming a three-dimensional structure described in item 5, since the predetermined pattern is a pattern in which three-dimensional shapes of the same shape are repeatedly arranged, the irregular roughness of the surface is alleviated, and the texture is improved. It is possible to form the surface of a good three-dimensional object.

(Section 6)
A manufacturing method for forming a three-dimensional structure according to any one of paragraphs 1 to 4, wherein the three-dimensional shape includes a first three-dimensional shape and a second three-dimensional shape having different shapes. , the predetermined pattern is a pattern in which the first three-dimensional shape and the second three-dimensional shape are regularly and repeatedly arranged.

According to the manufacturing method for forming a three-dimensional structure described in item 6, various patterns can be formed on the surface of the three-dimensional structure.

(Section 7)
A manufacturing method for forming a three-dimensional structure according to any one of items 1 to 6, wherein the predetermined pattern is the same on all surfaces of the three-dimensional structure.

According to the manufacturing method for forming a three-dimensional structure described in item 7, all surfaces of the three-dimensional structure can be made to have the same texture.

(Section 8)
The manufacturing method for forming a three-dimensional structure according to any one of items 1 to 6, wherein the predetermined pattern is different on at least one surface of the three-dimensional structure.

According to the manufacturing method for forming a three-dimensional structure described in item 8, at least one surface of the three-dimensional structure can be made to have a different texture.

(Section 9)
A manufacturing method for forming a three-dimensional structure according to any one of paragraphs 1 to 8, wherein the size of the three-dimensional shape is from 5 times to 150 times the particle diameter of the modeling material. .

According to the manufacturing method for forming a three-dimensional structure described in item 9, the feel when touching the surface with a human hand becomes more dominant in a shape based on a three-dimensional shape.

(Section 10)
A manufacturing method for forming a three-dimensional structure according to any one of items 1 to 9, wherein the modeling method includes powder sintering additive manufacturing, or heating by adding a melting accelerator to the modeling material. A modeling method is used.

According to the manufacturing method for forming a three-dimensional structure described in item 10, it is possible to form a three-dimensional structure with little anisotropy and excellent strength.

(Section 11)
A program according to one aspect is a program executed by a processor that converts three-dimensional data received by a manufacturing device that forms a three-dimensional object using powdered modeling material, and is a program that converts three-dimensional data of the three-dimensional object. a step of receiving the received three-dimensional data; a step of identifying a surface of the three-dimensional structure that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged; and shape data for forming a predetermined pattern on the identified surface. adding to the three-dimensional data.

According to the program described in Section 11, the data is converted into three-dimensional data that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged on the surface, which reduces the irregular roughness of the surface and creates a surface that feels nice to the touch. It is possible to form a three-dimensional structure with

(Section 12)
A program according to another aspect is a program executed by a processor that controls a manufacturing device that forms a three-dimensional object using a powder modeling material, and includes steps for receiving three-dimensional data of the three-dimensional object. , a step of forming a three-dimensional object using a modeling material based on the received three-dimensional data, and the step of forming the three-dimensional object includes: The method includes the steps of identifying a surface forming a predetermined pattern in which three-dimensional shapes are repeatedly arranged, and forming a predetermined pattern on the identified surface.

According to the program described in Section 12, a predetermined pattern in which three-dimensional shapes are repeatedly arranged is formed on the surface of a three-dimensional model, so that the irregular roughness of the surface is alleviated and the surface is pleasant to the touch. Three-dimensional objects can be formed.

The embodiments disclosed this time should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is indicated by the claims rather than the description of the embodiments described above, and it is intended that all changes within the meaning and range equivalent to the claims are included.

2 Surface, 2a, 2b, 2c, 2d Three-dimensional shape, 3 Roller, 4 Laser light source, 5 Galvanometer mirror, 6 Laser light, 7 Modeling area, 8 Container, 9 Head, 9a Dissolution promoter, 9b Surface decoration agent, 10, 10a Three-dimensional modeled object, 11, 12 Piston, 15 Heater, 20 Powder, 50 Powder sintering additive manufacturing device.

Claims (12)

A manufacturing method for forming a three-dimensional object using powder as a modeling material, the method comprising:
a step of receiving three-dimensional data of the three-dimensional structure;
identifying, among the surfaces of the three-dimensional structure in the received three-dimensional data, a surface that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged;
adding shape data for forming the predetermined pattern on the identified surface to the three-dimensional data;
A manufacturing method for forming a three-dimensional structure, the method comprising: forming the three-dimensional structure using the modeling material based on the three-dimensional data to which the shape data is added. A manufacturing method for forming a three-dimensional object using powder as a modeling material, the method comprising:
a step of receiving three-dimensional data of the three-dimensional structure;
forming the three-dimensional object using the modeling material based on the received three-dimensional data;
identifying, among the surfaces of the three-dimensional structure in the received three-dimensional data, a surface that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged;
A manufacturing method for forming a three-dimensional structure, the method comprising: forming the predetermined pattern on a specified surface. The manufacturing method for forming a three-dimensional structure according to claim 1 or 2, wherein the length of one side of the three-dimensional shape is greater than or equal to the particle diameter of the modeling material and less than or equal to ⅓ of the diameter of a finger. The tertiary material according to claim 1 or 2, further comprising the step of determining the predetermined pattern based on at least one of information on the particle size of the modeling material and information on the three-dimensional shape selected by the user. A manufacturing method for forming an original model. 3. The manufacturing method for forming a three-dimensional structure according to claim 1, wherein the predetermined pattern is a pattern in which the three-dimensional shapes having the same shape are repeatedly arranged. The three-dimensional shape has a first three-dimensional shape and a second three-dimensional shape that are different in shape,
3. The manufacturing method for forming a three-dimensional structure according to claim 1, wherein the predetermined pattern is a pattern in which the first three-dimensional shape and the second three-dimensional shape are repeatedly arranged. 3. The manufacturing method for forming a three-dimensional structure according to claim 1, wherein the predetermined pattern is the same on all surfaces of the three-dimensional structure. 3. The manufacturing method for forming a three-dimensional structure according to claim 1, wherein the predetermined pattern has a different pattern on at least one surface of the three-dimensional structure. The manufacturing method for forming a three-dimensional structure according to claim 1 or 2, wherein the size of the three-dimensional shape is from 5 times to 150 times the particle diameter of the modeling material. The method of forming the three-dimensional model according to claim 1 or 2, wherein the method of forming the three-dimensional model uses a powder sintering additive manufacturing method or a method of adding a melting accelerator to the modeling material and heating it. Manufacturing method to form. A program executed by a processor that converts three-dimensional data received by a manufacturing device that forms a three-dimensional object using a powder modeling material,
a step of receiving three-dimensional data of the three-dimensional structure;
identifying, among the surfaces of the three-dimensional structure in the received three-dimensional data, a surface that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged;
A program comprising: adding shape data for forming the predetermined pattern on the specified surface to the three-dimensional data. A program executed by a processor that controls a manufacturing device that forms a three-dimensional object using a powder modeling material,
a step of receiving three-dimensional data of the three-dimensional structure;
forming the three-dimensional structure using the modeling material based on the received three-dimensional data,
The step of forming the three-dimensional structure includes:
identifying, among the surfaces of the three-dimensional structure in the three-dimensional data, a surface that forms a predetermined pattern in which three-dimensional shapes are repeatedly arranged;
A program comprising: forming the predetermined pattern on the specified surface.

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