METHOD OF MANUFACTURING THREE-DIMENSIONAL STRUCTURE AND THREE-DIMENSIONAL STRUCTURE

• US 20150273520A1
• Filed: 03/19/2015
• Published: 10/01/2015
• Est. Priority Date: 03/26/2014
• Status: Abandoned Application

• Current Assignee: Seiko Epson Corporation (Seiko Group)
• Original Assignee: Seiko Epson Corporation (Seiko Group)
• Inventors: OKAMOTO, Eiji
• Application Number:
  US14/662,779
• Publication Number:
  US 20150273520A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B05D 5/02 to obtain a matt or rough surface
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B41J 2/0456 detecting drop size, volume or weight
• CPC Class Codes: B41J 2/0458 controlling heads based on heating elements forming bubbles
• CPC Class Codes: B41J 2/04581 controlling heads based on piezoelectric elements
• CPC Class Codes: Y10T 428/24612 Composite web or sheet

Abstract

A method of manufacturing a three-dimensional structure using three-dimensional data includes: discharging ink containing a curable resin from a droplet discharge head having a plurality of nozzles; curing the discharged ink; and measuring discharge amounts of the ink in the plurality of nozzles to create discharge amount data. Here, the three-dimensional data is corrected based on the discharge amount data.

Claims

1. A method of manufacturing a three-dimensional structure using three-dimensional data, comprising:

discharging ink containing a curable resin from a droplet discharge head having a plurality of nozzles;

curing the discharged ink; and

measuring discharge amounts of the ink in the plurality of nozzles to create discharge amount data;

wherein the three-dimensional data is corrected based on the discharge amount data.

2. The method of manufacturing a three-dimensional structure according to claim 1,

wherein the discharge amount data is created based on the results obtained by discharging the ink from the plurality of nozzles to form a predetermined test pattern and then measuring the height of the test pattern of the ink in a discharge direction.

3. The method of manufacturing a three-dimensional structure according to claim 1,

wherein, in the ink discharge process, when several kinds of ink are discharged, the discharge amount data are corrected using values of cure shrinkage of the several kinds of ink.

4. The method of manufacturing a three-dimensional structure according to claim 1,

wherein the three-dimensional data are corrected based on the discharge amount data and discharge position information of the plurality of nozzles.

5. The method of manufacturing a three-dimensional structure according to 1, further comprising:

creating two-dimensional sectional layer data by dividing the three-dimensional data of the three-dimensional structure into a plurality of two dimensional sectional layers,

wherein the two-dimensional sectional layer data are corrected based on the discharge amount data and discharge position information of the plurality of nozzles.

6. The method of manufacturing a three-dimensional structure according to 1, further comprising:

creating two-dimensional sectional layer data by dividing the three-dimensional data of the three-dimensional structure into a plurality of two dimensional sectional layers,

wherein, in the ink discharge process, the process is performed by superimposing the differential data of discharge amount of the nozzle having the maximum discharge amount of the plurality of nozzles and discharge amount of each of the plurality of other nozzles on a portion of the two-dimensional sectional layer data, the portion corresponding to the plurality of other nozzles.

7. The method of manufacturing a three-dimensional structure according to 1, further comprising:

creating two-dimensional sectional layer data by dividing the three-dimensional data of the three-dimensional structure into a plurality of two dimensional sectional layers,

wherein, in the ink discharge process, the process is performed by subtracting the differential data of discharge amount of the nozzle having the maximum discharge amount of the plurality of nozzles and discharge amount of each of the plurality of other nozzles from a portion of the two-dimensional sectional layer data, the portion corresponding to the plurality of nozzles.

8. The method of manufacturing a three-dimensional structure according to 1, further comprising:

creating two-dimensional sectional layer data by dividing the three-dimensional data of the three-dimensional structure into a plurality of two dimensional sectional layers,

wherein, in the ink discharge process, a portion of the two-dimensional sectional layer data, the portion corresponding to the plurality of nozzles, is corrected based on the differential data of the average discharge amount of the plurality of nozzles and the discharge amount of each of the plurality of nozzles.

9. A three-dimensional structure, which manufactured by the method according to claim 1.

10. A three-dimensional structure, which manufactured by the method according to claim 2.

11. A three-dimensional structure, which manufactured by the method according to claim 3.

12. A three-dimensional structure, which manufactured by the method according to claim 4.

13. A three-dimensional structure, which manufactured by the method according to claim 5.

14. A three-dimensional structure, which manufactured by the method according to claim 6.

15. A three-dimensional structure, which manufactured by the method according to claim 7.

16. A three-dimensional structure, which manufactured by the method according to claim 8.