This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2015-043879 filed Mar. 5, 2015.
The present invention relates to a shaping apparatus.
According to an aspect of the invention, there is provided a shaping apparatus including:
an ejection section that ejects a liquid droplet containing a curable resin and that overlaps layers formed of the liquid droplets to form a three-dimensional object; and
a forming section that forms, on the layer, a suppressing portion that suppresses a movement of the liquid droplet ejected by the ejection section on the layer.
Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
Hereinafter, exemplary embodiments will be described. First, the first exemplary embodiment and a modification example thereof are described and then, the second exemplary embodiment is described. In the following description, a ±Z direction in the drawings indicates an apparatus height direction (a Z direction and a −Z direction indicate an upward side and a downward side, respectively), a ±X direction indicates an apparatus width direction (an X direction and a −X direction indicate one end side and the other end side, respectively), and a direction (a ±Y direction) intersecting with a ±Z direction and a ±X direction indicates an apparatus depth direction (a Y direction and a −Y direction indicate a backward direction and a frontward direction, respectively).
Hereinafter, a shaping apparatus 10 according to the first exemplary embodiment will be described with reference to the drawings. First, a configuration of the shaping apparatus 10 according to the present exemplary embodiment is described. Then, a method of shaping a three-dimensional object VM by the shaping apparatus 10 according to the present exemplary embodiment will be described. Subsequently, effects of the present exemplary embodiment will be described.
The shaping apparatus 10 according to the present exemplary embodiment has a function of ejecting a liquid droplet D and of overlapping layers LR formed of the liquid droplets D and shaping the three-dimensional object VM (refer to
As shown in
As shown in
The ejection unit 20 has a function of ejecting the liquid droplet D and of overlapping the layers LR formed of the liquid droplets D to form the three-dimensional object VM. Here, the ejection unit 20 represents an example of an ejection section.
As shown in
The irradiation unit 30 travels together with the ejection unit 20 from the one end side to the other end side in the apparatus width direction and has a function of irradiating the liquid droplet D discharged by the ejection unit 20 with the light LB and of curing the liquid droplet D. Here, the irradiation unit 30 represents an example of a curing section. The light LB applied from the irradiation unit 30 according to the present exemplary embodiment is ultraviolet light as an example.
As shown in
The contact unit 40 has a function of forming a convex portion CX (refer to
As shown in
The contact roll 60 is long and is disposed to be adjacent to the irradiation unit 30 on the one end side in the apparatus width direction in a state in which the axial direction thereof is parallel to the longitudinal direction of the irradiation unit 30. As shown in
As shown in
Here, the contact unit 40 is further described. As described above, the contact roll 60 is configured to form the convex portions CX on the layer LR in accordance with the movement of the ejection unit 20 from the one end side to the other end side in the apparatus width direction. In this case, the contact roll 60 has a circumferential speed equal to a traveling speed of the ejection unit 20 in opposite directions to each other. That is, the circumferential speed of the contact roll 60 and the traveling speed of the contact roll 60 in the apparatus width direction have a relationship in which a relative speed becomes 0 therebetween. In addition, the contact roll 60 rotates around the axis and causes the lattice-shaped protrusion 66 to form a concavity into the layer LR so as to travel in the apparatus width direction. According to the above configuration, when the contact roll 60 travels from the one end side to the other end side in the apparatus width direction, a lattice-shaped concavity HG (refer to
The moving unit 50 has a function of causing the case CS to travel in the apparatus width direction and a function of causing the case CS to travel in the apparatus height direction. As shown in
The control unit 70 has a function of controlling each unit except for the control unit 70 constituting the shaping apparatus 10. The control unit 70 is configured to control the units except for the control unit 70 in response to data received from an external device (not shown). The specific function of the control unit 70 is provided in the following description of an operation of the shaping apparatus 10 to be described below.
The case CS is disposed at a home position by the moving unit 50 which is controlled by the control unit 70 in a period in which the shaping apparatus 10 does not perform a shaping operation, that is, in a period from the end of the shaping operation to the start of the shaping operation. Here, the home position represents a position of an end on the one end side in the apparatus width direction and an end on the lower side in the apparatus height direction. In a state in which the case CS is disposed at the home position, the ejection unit 20, the irradiation unit 30, and the contact unit 40 which are accommodated in the case CS are separated from the top surface of the base plate BD.
As above, the configuration of the shaping apparatus 10 according to the present exemplary embodiment is described.
Next, a method of shaping the three-dimensional object VM by the shaping apparatus 10 according to the present exemplary embodiment (hereinafter, referred to as a shaping method according to the present exemplary embodiment) is described with reference to the drawings.
First, when the control unit 70 receives data from an external device, the control unit 70 converts data (that is, three-dimensional data) of the three-dimensional object VM contained in the data into data (that is, two-dimensional data) of a plural layers LR.
Subsequently, the control unit 70 controls the moving unit 50 such that the case CS disposed at the home position travels from the one end side to the other end side in the apparatus width direction and causes the ejection unit 20 to eject the liquid droplet D. The control unit 70 causes the irradiation unit 30 that moves together with the ejection unit 20 to perform irradiation with the light LB. In addition, the control unit 70 causes the driving source of the contact unit 40 to drive and causes the contact roll 60 that moves together with the ejection unit 20 to rotate around the axis. Through the above operations performed by the control unit 70, the liquid droplets D ejected from the ejection unit 20 are cured immediately after landing on the base plate BD by the light LB and are pressed and deformed by the lattice-shaped protrusion 66 of the contact roll 60 (refer to
Subsequently, the control unit 70 controls the moving unit 50 such that the case CS travels to a position on the upper side in the apparatus height direction and further controls the moving unit 50 such that the case CS travels to the end on the one end side in the apparatus width direction. The position on the upper side in the apparatus height direction to which the moving unit 50 causes the case CS to travel becomes a position at which the ejection unit 20, the irradiation unit 30, and the contact unit 40 which are accommodated in the case CS are separated from the first layer LR.
The second to final layers LR are formed by repeating the process of forming the first layer LR described above. In a process of forming the second to final layers LR, the liquid droplets D ejected from the ejection unit 20 land on the layer LR on which the plural convex portions CX are formed (refer to
As above, the shaping method according to the present exemplary embodiment is described.
Next, effects (first to sixth effects) of the present exemplary embodiment will be described with reference to the drawings.
The first effect is described based on a comparison between the shaping apparatus 10 according to the present exemplary embodiment and a shaping apparatus (not shown) according to a first comparative embodiment to be described below. In the following description, in a case where the same components are used in the first comparative embodiment as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
Unlike the shaping apparatus 10 according to the present exemplary embodiment, the shaping apparatus according to the first comparative embodiment does not include the contact unit 40. Therefore, the shaping apparatus according to the first comparative embodiment overlaps the layers LR without forming a convex portion CX on the formed layer LR and shapes the three-dimensional object VM. The shaping apparatus according to the first comparative embodiment has the same configuration as the shaping apparatus 10 according to the present exemplary embodiment except for the above difference.
The following description is provided with reference to
As above, when the adjacent liquid droplets D1 and D2 land on the layer LR using the shaping apparatus according to the first comparative embodiment, there is concern that the liquid droplets D1 and D2 will move to and will be cured at the positions shifted from the landing positions D1A and D2A, respectively. As shown in
Unlike the shaping apparatus according to the first comparative embodiment, the shaping apparatus 10 according to the present exemplary embodiment includes the contact unit 40 which forms the plural convex portions CX on the formed layer LR. Therefore, when the adjacent liquid droplets D land on the layer LR using the shaping apparatus 10 according to the present exemplary embodiment, these liquid droplets D are pinned by the convex portions CX formed on the layer LR and are unlikely to spread like a liquid droplet D1 in
A state in which the liquid droplets D1, D2, and D3 are pinned by the convex portions CX means a state in which it is not possible for the liquid droplets D1, D2, and D3 to be separated from the convex portions CX. In the case of the present exemplary embodiment, as shown in
Accordingly, the shaping apparatus 10 according to the present exemplary embodiment may shape a three-dimensional object with high accuracy compared to a shaping apparatus which ejects the liquid droplet Don the layer LR, overlaps the layers LR, and shapes a three-dimensional object, without forming the suppressing portion which suppresses a movement of the liquid droplet D on the layer LR formed of the liquid droplets D.
Next, the second effect is described based on a comparison between the shaping apparatus 10 according to the present exemplary embodiment and a shaping apparatus (not shown) according to a second comparative embodiment to be described below. In the following description, in a case where the same components are used in the second comparative embodiment as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
Unlike the shaping apparatus 10 according to the present exemplary embodiment, in the shaping apparatus according to the second comparative embodiment, a contact roll forms plural convex portions CX such that the plural convex portions CX are formed on the layer LR at an interval that is more than two times as large as the average landing diameter d of the liquid droplet D. The shaping apparatus according to the second comparative embodiment has the same configuration as the shaping apparatus 10 according to the present exemplary embodiment except for the above difference. The shaping apparatus according to the second comparative embodiment is included in a technical scope of the invention.
The shaping apparatus according to the second comparative embodiment has the first effect described above. However, when a three-dimensional object VM is formed using the shaping apparatus according to the second comparative embodiment, the liquid droplet D landing on the layer LR does not come into contact with the convex portions CX in some cases. The liquid droplet D is not pinned by the convex portion CX.
In contrast, in the case of the present exemplary embodiment, the plural convex portions CX are disposed at an interval that is two times as large as the average landing diameter d of the liquid droplet D. Therefore, in the case of the present exemplary embodiment, as shown in
According to the shaping apparatus 10 according to the present exemplary embodiment compared to the shaping apparatus in which the contact unit forms the plural convex portions CX such that convex portions CX are formed to be adjacent at an interval that is more than two time as large as the landing diameter of the liquid droplet D, it is possible to form the three-dimensional object VM with high accuracy. In the case of the present exemplary embodiment, as above, the plural convex portions CX are disposed on the layer LR at an interval that is two times as large as the average landing diameter d of the liquid droplet D; however, it is needless to say that the effect is also achieved in a case in which the plural convex portions CX are disposed at an interval that is less than two times as large as the average landing diameter d of the liquid droplet D.
Next, the third effect will be described. As shown in
Next, the fourth effect is described based on a comparison between the shaping apparatus 10 according to the present exemplary embodiment and a shaping apparatus (not shown) according to a third comparative embodiment to be described below. In the following description, in a case where the same components are used in the third comparative embodiment as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
Unlike the shaping apparatus 10 according to the present exemplary embodiment, in the shaping apparatus according to the third comparative embodiment, the irradiation unit 30 and the contact roll 60 are disposed in a state of switching the positions thereof. That is, the ejection unit 20, the contact roll 60, and the irradiation unit 30 are arranged and accommodated in this order in the case CS. The shaping apparatus according to the third comparative embodiment has the same configuration as the shaping apparatus 10 according to the present exemplary embodiment except for the above difference. The shaping apparatus according to the third comparative embodiment is included in a technical scope of the invention.
In a case where a three-dimensional object VM is formed using the shaping apparatus according to the third comparative embodiment, the lattice-shaped protrusion 66 of the contact roll 60 presses down on and deforms the liquid droplet D before the liquid droplet D is irradiated and cured with the light LB from the irradiation unit 30, and then the irradiation unit 30 irradiates the liquid droplet D with the light LB. Therefore, it is not possible for the liquid droplet D to maintain the deformed shape until the liquid droplet D is irradiated and cured with the light LB from the irradiation unit 30 after being deformed by the contact roll 60. The shaping apparatus according to the third comparative embodiment achieves the first and second effects described above.
Accordingly, according to the shaping apparatus 10 according to the present exemplary embodiment compared to the shaping apparatus in which the layer LR is cured after the plural convex portions CX are formed on the layer LR, it is possible to form the plural convex portions CX having stable shapes.
Next, the fifth effect is described based on a comparison between the shaping apparatus 10 according to the present exemplary embodiment and a shaping apparatus (not shown) according to a fourth comparative embodiment to be described below. In the following description, in a case where the same components are used in the fourth comparative embodiment as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
Unlike the shaping apparatus 10 according to the present exemplary embodiment, in the shaping apparatus according to the fourth comparative embodiment, the contact unit is a member which is provided with plural blades in the apparatus width direction on a long plate. The shaping apparatus according to the fourth comparative embodiment has the same configuration as the shaping apparatus 10 according to the present exemplary embodiment except for the above difference. The shaping apparatus according to the fourth comparative embodiment is included in a technical scope of the invention.
When a three-dimensional object VM is formed using the shaping apparatus according to the fourth comparative embodiment, it is possible to form the plural convex portions on the layer LR in the traveling direction (direction facing the plural blades) of the case CS. However, the contact unit according to the fourth comparative embodiment travels from the one end side to the other end side in the apparatus width direction, and scratches the layer LR in a direction (for example, apparatus depth direction) different from the traveling direction of the case CS. Thus, it is not possible to form a convex portion. The shaping apparatus according to the fourth comparative embodiment has the first to fourth effects described above.
In contrast, the lattice-shaped protrusion 66 is formed on the outer circumference of the cylindrical section 64 of the contact roll 60 according to the present exemplary embodiment. The lattice-shaped protrusion 66 comes into contact with and presses down on the layer LR in accordance with the rotation of the contact roll 60 around the axis and the lattice-shaped convex portions CX facing plural directions (in the case of the present exemplary embodiment, for example, two directions of the apparatus width direction and the apparatus depth direction) are formed on the layer LR.
Accordingly, according to the shaping apparatus 10 according to the present exemplary embodiment, it is possible to form the plural convex portions CX facing the plural directions, all at once on the layer LR.
Next, the sixth effect is described based on a comparison between the shaping apparatus 10 according to the present exemplary embodiment and a shaping apparatus (not shown) according to a fifth comparative embodiment to be described below. In the following description, in a case where the same components are used in the fifth comparative embodiment as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
Unlike the shaping apparatus 10 according to the present exemplary embodiment, in the shaping apparatus according to the fifth comparative embodiment, the contact unit is not accommodated in the case CS. The contact unit according to the fifth comparative embodiment is formed of a plate having one surface on which a lattice-shaped protrusion is formed. In the shaping apparatus according to the fifth comparative embodiment, the ejection unit 20 ejects the liquid droplet D and the layer LR is formed. After the irradiation unit 30 irradiates and cures the layer LR with the light LB, the contact unit presses down on the layer LR from the upper side such that the plural convex portions CX are formed on the layer LR. The shaping apparatus according to the fifth comparative embodiment has the same configuration as the shaping apparatus 10 according to the present exemplary embodiment except for the above difference. The shaping apparatus according to the fifth comparative embodiment is included in a technical scope of the invention.
When a three-dimensional object VM is formed using the shaping apparatus according to the fifth comparative embodiment, it is possible to form the plural convex portions CX on the layer LR. However, in the shaping apparatus according to the fifth comparative embodiment, it is not possible to form the plural convex portions CX on the layer LR in accordance with an ejection operation of the liquid droplet D by the ejection unit 20 and a curing operation of the layer LR by the irradiation unit 30. In the case of the fifth comparative embodiment, in order to form the plural convex portions CX, the forming process needs to be performed at a timing after the ejection operation of the liquid droplet D by the ejection unit 20 and the curing operation of the layer LR by the irradiation unit 30.
In contrast, in the case of the present exemplary embodiment, as above, the ejection unit 20, the irradiation unit 30, and the contact unit 40 are accommodated in the case CS and the operations are performed in equilibrium in accordance with the traveling of the case CS. Accordingly, in the shaping apparatus 10 according to the present exemplary embodiment compared to the shaping apparatus in which the contact unit is not formed to be able to travel together with the ejection unit 20 and the irradiation unit 30 and is formed of a plate having one surface on which the protrusions are formed, it is possible to form the three-dimensional object VM in a short amount of time.
Next, a shaping apparatus 10A according to a modification example of the first exemplary embodiment will be described with reference to the drawings. First, a configuration of the shaping apparatus 10A of the modification example is described. Subsequently, an operation by the shaping apparatus 10A of the modification example will be described. Then, effects of the modification example will be described. In the following description, in a case where the same components are used in the modification example as the components used in the present exemplary embodiment, a description is provided by attaching the same reference signs or the like to the components or the like.
As shown in
A shaping method of the modification example is performed in the same order (order of finishing through forming the layers LR after the data conversion), as in the shaping method according to the first exemplary embodiment.
Effects of the modification example are the same as the effects of the first exemplary embodiment.
Next, a shaping apparatus 10B according to the second exemplary embodiment will be described with reference to the drawings. First, a configuration of the shaping apparatus 10B according to the present exemplary embodiment is described. Substantially, an operation of the shaping apparatus 10B according to the present exemplary embodiment will be described. Then, effects of the present exemplary embodiment will be described. In the following description, in a case where the same components are used in the present exemplary embodiment as the components used in the first exemplary embodiment and the modification examples thereof, a description is provided by attaching the same reference signs or the like to the components or the like.
As shown in
A shaping method according to the present exemplary embodiment is performed in the same order (order of finishing through forming the layers LR after the data conversion) as in the shaping method according to the first exemplary embodiment. Here, a difference between the present exemplary embodiment and the first exemplary embodiment, that is, adhering the particle TP to the layer LR, is described. While the contact unit 40B according to the present exemplary embodiment travels from the one end side to the other end side in the apparatus width direction in accordance with the movement of the case CS, the control unit 70 causes the shutter 96 to move at a predetermined timing (for example, timing at which the contact roll 60B rotates by 2d in the circumferential direction). The dropping unit 90 causes the particle TP to be disposed on the outer circumference of the contact roll 60B at intervals 2d in the circumferential direction (refer to
As above, a liquid forming the liquid droplet D according to the present exemplary embodiment is transparent. Therefore, in the case of the present exemplary embodiment, it is possible to shape a three-dimensional object VM in a color by the color of the particle TP. The other effects of the present exemplary embodiment are the same as those in the cases of the first exemplary embodiment and the modification examples.
In the case of the present exemplary embodiment, as in the third comparative embodiment described above, the irradiation unit 30 and the contact roll 60 may be disposed in a state of switching the positions thereof, the liquid droplet D may be irradiated with the light LB by the irradiation unit 30 after the particle TP adheres to the liquid droplet D, and the liquid droplet D may be cured such that the layer LR may be formed. In this case, a part of the particles TP are buried due to its own weight in the liquid droplet D before curing such that adhesiveness of the particles TP is improved.
As above, although a specific exemplary embodiment of the invention has been described in detail, the invention is not limited to the exemplary embodiments described above and other various exemplary embodiments may be performed within a scope of the invention.
For example, in the description of the exemplary embodiments, the ejection unit 20, the irradiation unit 30, and the contact unit 40 are accommodated in the case CS and travel integrally with each other in the apparatus width direction. However, the ejection unit 20, the irradiation unit 30, and the contact unit 40 may be configured to travel separately.
In addition, in the description of the exemplary embodiment, a light curable resin represents an example of the curable resin. However, as another aspect included in the technical scope of the invention, the shaping apparatus may use a thermosetting resin instead of the light curable resin. In this case, a layer configured to contain the thermosetting resin may be heated by light or may be heated by hot air.
In addition, in the description of the exemplary embodiments, the light curable resin represents an example of the curable resin. However, as another aspect included in the technical scope of the invention, the shaping apparatus may use a thermoplastic resin instead of the light curable resin. In this case, a heater is provided in a head, and it is possible for a liquid to be ejected as a liquid droplet in a state in which the liquid in the head is heated, and it is possible to form a layer formed of the liquid droplets cooled at room temperature. Therefore, in the shaping apparatus which forms the three-dimensional object VM with the liquid droplet containing the thermoplastic resin, there is no need to provide an irradiation section that irradiates the formed layer with light and a section that applies heat.
The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
Number | Date | Country | Kind |
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2015-043879 | Mar 2015 | JP | national |