THREE-DIMENSIONAL OBJECT MANUFACTURING METHOD AND THREE-DIMENSIONAL OBJECT MANUFACTURING SYSTEM

• US 20200130259A1
• Filed: 10/09/2019
• Published: 04/30/2020
• Est. Priority Date: 10/29/2018
• Status: Active Grant

• Current Assignee: Mimaki Engineering Co., Ltd.
• Original Assignee: Mimaki Engineering Co., Ltd.
• Inventors: Hakkaku, Kunio, Kurihara, Katsuyuki, Katou, Tetsuya
• Granted Patent: US 11,407,167 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/218 Rollers
• 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 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 40/00 Auxiliary operations or equipment, e.g. for material handling
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

In a three-dimensional object manufacturing method using a three-dimensional object manufacturing device for manufacturing a three-dimensional object by layering and stacking an ink layer in which a surface is flattened by a flattening roller for removing one part of the surface of the ink layer to adjust a thickness of the ink layer to a thickness t, where when forming ink layers with an inkjet head, an ink ejection amount reduction region in which an ejection amount of ink ejected by the inkjet head is reduced from an amount corresponding to the thickness t in a part corresponding to an interior of the three-dimensional object, and when forming the ink layers on an upper side of the specific ink layers with the inkjet head, an ejection amount of ink ejected by the inkjet head is increased from an amount corresponding to the thickness t.

Claims

1. A three-dimensional object manufacturing method, comprising:

providing a three-dimensional object manufacturing device, including;

an inkjet head for forming an ink layer;

a flattening mechanism for removing one part of a surface of the ink layer formed by the inkjet head to flatten the surface and adjust a thickness of the ink layer to a specific thickness; and

a controller for layering and stacking the ink layer in which the surface is flattened by the flattening mechanism to manufacture a three-dimensional object;

performing an ink ejection amount reducing step of forming an ink ejection amount reduction region in which an ejection amount of ink ejected by the inkjet head is reduced from an amount corresponding to the specific thickness in at least one part of a part corresponding to an interior of the three-dimensional object, when forming the ink layer that is specific with the inkjet head; and

performing an ink ejection amount increasing step of increasing an ejection amount of ink ejected by the inkjet head with respect to a region in which a range in an extending direction of the ink layer overlaps the ink ejection amount reduction region from an amount corresponding to the specific thickness, when forming the ink layer on an upper side of the ink layer that is specific with the inkjet head.

2. The three-dimensional object manufacturing method according to claim 1, wherein

the ink ejection amount reducing step is a step of forming the ink ejection amount reduction region by forming cavity data in at least one part of a part corresponding to the ink ejection amount reduction region in manufacturing data used by the three-dimensional object manufacturing device.

3. The three-dimensional object manufacturing method according to claim 1, wherein

the three-dimensional object includes a target shaped object to be aimed,

the target shaped object includes a color layer to be visually recognized from an outside, and

the ink ejection amount reduction region is disposed on an inner side of the color layer in the target shaped object.

4. The three-dimensional object manufacturing method according to claim 2, wherein

the three-dimensional object includes a target shaped object to be aimed,

the target shaped object includes a color layer to be visually recognized from an outside, and

the ink ejection amount reduction region is disposed on an inner side of the color layer in the target shaped object.

5. The three-dimensional object manufacturing method according to claim 1, wherein

the three-dimensional object includes:

a target shaped object to be aimed; and

a support portion for supporting at least one part of the target shaped object, and

the ink ejection amount reducing step is a step of forming the ink ejection amount reduction region in at least one part of the support portion.

6. The three-dimensional object manufacturing method according to claim 2, wherein

the three-dimensional object includes:

a target shaped object to be aimed; and

a support portion for supporting at least one part of the target shaped object, and

the ink ejection amount reducing step is a step of forming the ink ejection amount reduction region in at least one part of the support portion.

7. The three-dimensional object manufacturing method according to claim 1, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

8. The three-dimensional object manufacturing method according to claim 2, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

9. The three-dimensional object manufacturing method according to claim 3, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

10. The three-dimensional object manufacturing method according to claim 4, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

11. The three-dimensional object manufacturing method according to claim 5, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

12. The three-dimensional object manufacturing method according to claim 6, wherein

the ink ejection amount reducing step is a step of forming a plurality of the ink ejection amount reduction regions in the three-dimensional object in the extending direction of the ink layer.

13. A three-dimensional object manufacturing system, comprising:

a three-dimensional object manufacturing device, including;

an inkjet head for forming an ink layer;

a flattening mechanism for removing one part of a surface of the ink layer formed by the inkjet head to flatten the surface and adjust a thickness of the ink layer to a specific thickness; and

a controller for layering and stacking the ink layer in which the surface is flattened by the flattening mechanism to manufacture a three-dimensional object,

wherein the controller is configured to;

form an ink ejection amount reduction region in which an ejection amount of ink ejected by the inkjet head is reduced from an amount corresponding to the specific thickness in at least one part of a part corresponding to an interior of the three-dimensional object, when forming the ink layer that is specific with the inkjet head, and

increase an ejection amount of ink ejected by the inkjet head with respect to a region in which a range in an extending direction of the ink layer overlaps the ink ejection amount reduction region from an amount corresponding to the specific thickness, when forming the ink layer on an upper side of the ink layer that is specific with the inkjet head.