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WO2016067584A1 - Procédé de fabrication de structure tridimensionnelle, appareil de fabrication de structure tridimensionnelle et structure tridimensionnelle - Google Patents

Procédé de fabrication de structure tridimensionnelle, appareil de fabrication de structure tridimensionnelle et structure tridimensionnelle Download PDF

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Publication number
WO2016067584A1
WO2016067584A1 PCT/JP2015/005357 JP2015005357W WO2016067584A1 WO 2016067584 A1 WO2016067584 A1 WO 2016067584A1 JP 2015005357 W JP2015005357 W JP 2015005357W WO 2016067584 A1 WO2016067584 A1 WO 2016067584A1
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Prior art keywords
liquid
layer
dimensional structure
manufacturing
cured product
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PCT/JP2015/005357
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English (en)
Inventor
Tomoaki Takahashi
Toshimitsu Hirai
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Seiko Epson Corp
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Seiko Epson Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/165—Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/188—Processes of additive manufacturing involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control

Definitions

  • the present invention relates to a method for manufacturing a three-dimensional structure, a three-dimensional structure manufacturing apparatus, and a three-dimensional structure.
  • a technology for forming a three-dimensional structure by forming powder layers (layers) using a composition including powder (particles) and by stacking these layers is known (for example, refer to PTL 1).
  • a three-dimensional structure is formed by repeating the following operations. First, powder is spread thinly in a uniform thickness to form a powder layer, a binder material (liquid) is applied to only a desired portion of the powder layer, and powder (particles) is bound to each other, whereby a bound portion (cured portion) is formed.
  • a member having a thin plate-shape hereinafter, referred to as a "cross-section member" is formed at the bound portion formed by binding of the powder to each other.
  • a three-dimensional structure can be formed by stacking cross-section members (bound portions) having a thin plate-shape layer by layer by repeating such operations.
  • An advantage of some aspects of the invention is to provide a method for manufacturing a three-dimensional structure and a three-dimensional structure manufacturing apparatus, capable of efficiently manufacturing a three-dimensional structure which has excellent dimensional accuracy and mechanical strength, and a three-dimensional structure which has excellent dimensional accuracy and mechanical strength.
  • a method for manufacturing a three-dimensional structure according to an aspect of the invention is a method for manufacturing a three-dimensional structure by repeating a treatment of forming a layer and discharging a liquid to the layer, including: a layer forming step of forming the layer having a predetermined thickness using a layer forming composition including particles; a liquid applying step of applying the liquid to the layer; and a curing step of forming a cured portion by curing the liquid, in which based on a height of an upper surface of a cured product formed using the liquid, a thickness of the layer to be newly formed after formation of the cured product is determined.
  • a method for manufacturing a three-dimensional structure is a method for manufacturing a three-dimensional structure by repeating a treatment of forming a layer and discharging a liquid to the layer, including: a layer forming step of forming the layer having a predetermined thickness using a layer forming composition including particles; a liquid applying step of applying the liquid to the layer; and a curing step of forming a cured portion by curing the liquid, in which a height of a cured product formed using the liquid is measured, and based on the measurement result, a thickness of the layer to be newly formed after formation of the cured product is determined.
  • a method for manufacturing a three-dimensional structure is a method for manufacturing a three-dimensional structure by repeating a treatment of forming a layer and discharging a liquid to the layer, including: a layer forming step of forming the layer having a predetermined thickness by flattening a layer forming composition including particles, using a flattening device; a liquid applying step of applying the liquid to the layer; and a curing step of forming a cured portion by curing the liquid, in which the flattening device is brought into contact with an upper surface of a cured product formed using the liquid, and based on the contact surface, the layer having a predetermined thickness is formed.
  • the cured product is formed at a second region different from a first region where a portion configuring an entity portion of the three-dimensional structure of interest on the forming stage is formed.
  • the second region is provided on the outer peripheral side of the first region.
  • a discharge pattern density of the liquid in the second region is equal to a discharge pattern density of the liquid in the first region.
  • the cured product is formed so as to be stacked over a plurality of steps, to correspond to the plurality of layers.
  • a cured product formed in any step, of a plurality of the cured products formed by being stacked over a plurality of steps is defined as a first cured product
  • a cured product formed in a later step than the first cured product is defined as a second cured product
  • the second cured product does not have a region not overlapping with the first cured product, when seen in a plan view.
  • the method for manufacturing a three-dimensional structure of the aspect of the invention further includes a first liquid applying step of applying the liquid to the layer in a state of including a solvent after the layer forming step is performed using the layer forming composition including the particles and the solvent; a first curing step of curing the liquid applied to the layer; and a solvent removing step of removing the solvent from the layer.
  • the method for manufacturing a three-dimensional structure of the aspect of the invention further includes a second liquid applying step of applying the liquid to the layer in a state in which the solvent is removed after the solvent removing step and penetrating the liquid into the layer; and a second curing step of curing the liquid penetrated into the layer.
  • a three-dimensional structure manufacturing apparatus is a three-dimensional structure manufacturing apparatus for manufacturing a three-dimensional structure by repeating a treatment of forming a layer and discharging a liquid to the layer, including: a stage that forms the layer using a layer forming composition including particles; a liquid applying device that applies a liquid to the layer; and a curing device that cures the liquid, in which based on a height of an upper surface of a cured product formed using the liquid, a thickness of the layer to be newly formed after formation of the cured product is determined.
  • a three-dimensional structure according to still yet another aspect of the invention is a three-dimensional structure manufactured using the method for manufacturing a three-dimensional structure of the aspect of the invention.
  • a three-dimensional structure according to further another aspect of the invention is manufactured using the three-dimensional structure manufacturing apparatus of the aspect of the invention.
  • Fig. 1A is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1B is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1C is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1D is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1A is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1B is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the
  • FIG. 1E is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1F is a cross-sectional view schematically showing a step in a first embodiment of a method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1G is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1H is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • FIG. 1I is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1J is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1K is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1L is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1M is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1N is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1O is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1P is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1Q is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1N is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1O is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1P is a
  • FIG. 1R is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1S is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1T is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2A is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1R is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1S is a cross-sectional view schematically showing a step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 1T is a
  • FIG. 2B is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2C is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2D is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2E is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • FIG. 2F is a cross-sectional view schematically showing a step in a second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2G is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2H is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2I is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • FIG. 2J is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2K is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2L is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2M is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2N is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2O is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2P is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2Q is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2R is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • FIG. 2S is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 2T is a cross-sectional view schematically showing a step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • Fig. 3 is a cross-sectional view schematically showing a preferred embodiment of a three-dimensional structure manufacturing apparatus according to the invention.
  • FIGS. 1A to 1T are cross-sectional views schematically showing each step in the first embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • the method for manufacturing a three-dimensional structure 10 of the embodiment has a layer forming step (Fig. 1D, Fig. 1K, and Fig. 1R) of forming a layer 1 having a predetermined thickness using a layer forming composition 1' including particles 11, a liquid applying step (Fig. 1E, Fig. 1H, Fig. 1L, and Fig. 1O) of applying a liquid (cured portion forming liquid) 2' used in formation of a cured portion 2 (a first cured portion 2A) to the layer 1, and a curing step (Fig. 1F, Fig. 1I, Fig. 1M, and Fig. 1P) of forming the cured portion 2 by curing the liquid 2'.
  • a layer forming step Fig. 1D, Fig. 1K, and Fig. 1R
  • a liquid applying step Fig. 1E, Fig. 1H, Fig. 1L, and Fig. 1O
  • a curing step Fig. 1F, Fig. 1I
  • the liquid 2' used in formation of the cured portion 2 configuring an intended three-dimensional structure 10 is applied to a second region M412 which is a region different from a first region M411 which is a region at which the intended three-dimensional structure 10 is manufactured; and in the curing step, the cured portion 2 is formed by curing the liquid 2' applied to the first region M411, and a cured product 6 having the same height as that of the cured portion 2 is formed by curing the liquid 2' applied to the second region M412.
  • the thickness of the layer 1 is determined based on the height of the upper surface of the cured product 6 (Fig. 1J and Fig. 1Q).
  • the flattening device M42 in the layer forming step, is brought into contact with the upper surface of the cured product 6, and, based on the height (contact surface) at which the flattening device M42 is in contact with the cured product 6, the layer 1 having a predetermined thickness is formed (refer to Fig. 1J and Fig. 1Q).
  • the cured product 6 is formed at the second region M412 different from the first region M411 where a portion configuring an entity portion of an intended three-dimensional structure 10 is formed, on the stage M41.
  • the flattening device M42 when the flattening device M42 is brought into contact with the upper surface of the cured product 6 (when the thickness of the layer to be newly formed is determined), it is possible to more reliably prevent an occurrence of unintended deformation in the layer 1 according to the cured portion 2 or forming of the intended three-dimensional structure 10. As a result, it is possible to make the dimensional accuracy and the reliability of the finally obtained three-dimensional structure 10 particularly excellent.
  • the second region M412 is provided on the outer peripheral side of the first region M411.
  • the second region M412 is provided on the upstream side of the first region M411.
  • the relative height of the flattening device M42 can be adjusted, and due to this, it is possible to efficiently perform formation of the layer 1 by the flattening device M42, and it is possible to make the productivity of the three-dimensional structure 10 particularly excellent.
  • the discharge pattern density of the liquid 2' in the second region M412 is preferably equal to the discharge pattern density of the liquid 2' in the first region M411.
  • the liquid 2' is preferably discharged at 720 dpi even in the second region M 412.
  • the cured product 6 is preferably formed so as to be stacked over a plurality of steps (Fig. 1B, Fig. 1F, Fig. 1M, and Fig. 1S), to correspond to the plurality of layers 1.
  • all of the plurality of cured products 6 formed by being stacked over several steps have the same shape and the same area.
  • a cured product formed in any step, of the plurality of cured products 6 formed by being stacked over a plurality of steps is defined as a first cured product
  • a cured product formed in a later step than the first cured product, of the plurality of cured products 6 formed by being stacked over a plurality of steps is defined as a second cured product, the second cured product does not have a region not overlapping with the first cured product, when seen in a plan view.
  • the method for manufacturing a three-dimensional structure according to the invention may have a layer forming step, a liquid applying step, and a curing step, and the method for manufacturing the three-dimensional structure 10 of the embodiment has a layer forming step of forming the layer 1 using the layer forming composition 1' including the particles 11 and the solvent 12 (Fig. 1C, Fig. 1D, Fig. 1J, Fig. 1K, Fig. 1Q, and Fig. 1R), a first liquid applying step (Fig. 1E and Fig. 1L) of applying the liquid (cured portion forming liquid) 2' used in formation of the cured portion 2 (first cured portion 2A) on the layer 1 in a state of including the solvent 12, a first curing step (Fig. 1F and Fig.
  • the method for manufacturing the three-dimensional structure 10 of the embodiment further has an unbound particle removing step (Fig. 1T) of removing particles which are not bound by the cured portion 2, of the particles 11 configuring each layer 1.
  • the embodiment has a third liquid applying step (Fig. 1A) of applying the liquid (cured portion forming liquid) 2' used in formation of the cured portion 2 (third cured portion 2C) to the stage M41 on which the layer 1 (layer 1 formed using a layer forming composition 1') is not formed before the first layer forming step, and a third curing step (Fig. 1B) of forming the cured portion 2 (third cured portion 2C) by curing the liquid 2'.
  • a third liquid applying step Fig. 1A
  • a third curing step Fig. 1B
  • the cured portion 2 (cured portion 2 not including the particles 11) buried in the lowermost layer 1, and the layer 1 not including the cured portion 2 not including the particles 11 is not formed, it is possible to make the productivity of the three-dimensional structure 10 particularly excellent. Since, in the finally obtained three-dimensional structure 10, the cured portion 2 configuring an outer surface when viewed from the side can be unified with a portion configured of a material not containing the particles 11, it is possible to make an aesthetic appearance of the overall three-dimensional structure 10 particularly excellent.
  • the liquid 2' is applied to the first region M411, and the liquid 2' is also applied to the second region M412, and in the third curing step, the cured portion 2 (third cured portion 2C) is formed by curing the liquid 2' applied to the first region M411, and the cured product 6 is formed by curing the liquid 2' applied to the second region M412.
  • the liquid 2' used in formation of the cured portion 2 (third cured portion 2C) on the first region M411 of the stage M41 on which the layer 1 is not formed is applied by an ink jet method (refer to Fig. 1A).
  • the liquid 2' is applied to a portion corresponding to a part of the finally obtained three-dimensional structure 10.
  • the liquid 2' is applied to a portion corresponding to a region near the outer surface where the finally obtained three-dimensional structure 10 can be visually recognized when viewed from the side.
  • the cured portion 2 configuring an outer surface when viewed from the side can be unified with a portion configured of a material not containing the particles 11, it is possible to make an aesthetic appearance of the overall three-dimensional structure 10 particularly excellent.
  • the liquid 2' is applied by an ink jet method, and thus, it is possible to reproducibly apply the liquid 2' even in a case where the applying pattern of the liquid 2' has a fine shape. As a result, it is possible to make the dimensional accuracy of the finally obtained three-dimensional structure 10 particularly high.
  • the liquid 2' is also applied to the second region M412 of the stage M41.
  • the liquid 2' includes at least a polymerizable compound (uncured curable resin material) (same is also applied with respect to the liquid 2' applied in the first liquid applying step described below and the liquid 2' applied in the second liquid applying step).
  • a polymerizable compound uncured curable resin material
  • the liquid 2' will be described below in detail.
  • thermosetting resin thermosetting resin
  • photocurable polymerizable compound photocurable resin
  • the liquid 2' applied to the second region M412 of the stage M41 is also subjected to the curing treatment as described above, and as a result, the cured product 6 is formed.
  • a series of steps including application of the liquid 2' (liquid applying step) and curing of the liquid 2' (curing step) may be repeatedly performed before performing the step described below.
  • the layer 1 having a predetermined thickness is formed using the composition (layer forming composition) 1' including the particles 11 and the solvent 12 (refer to Fig. 1C, Fig. 1D, Fig. 1J, Fig. 1K, Fig. 1Q, and Fig. 1R).
  • the layer 1 having a predetermined thickness is formed on the stage (support) M41 provided with the cured portion 2 (third cured portion 2C) using the composition (layer forming composition) 1' including the particles 11 and the solvent 12 (Fig. 1C and Fig. 1D), and in the second and subsequent layer formation steps, the new layer 1 having a predetermined thickness is formed on the layer 1 (in the configuration in the figures, the layer 1 in which a bound portion 3 is formed) using the composition (layer forming composition) 1' including the particles 11 and the solvent 12 (Fig. 1J, Fig. 1K, Fig. 1Q, and Fig. 1R).
  • the composition (layer forming composition) 1' will be described below in detail.
  • the layer forming step which is performed in a state in which the cured portion 2 (third cured portion 2C) formed in the third liquid applying step described above is exposed on the outer surface at least a part of the cured portion 2 (third cured portion 2C) is buried (refer to Fig. 1D)
  • the layer forming step which is performed in a state in which the cured portion 2 (first cured portion 2A) formed in the first liquid applying step described below is exposed on the outer surface at least a part of the cured portion 2 (first cured portion 2A) is buried (refer to Fig. 1K and Fig. 1R).
  • the second cured portion 2B is formed in a subsequent step on the portion in contact with the cured portion 2 of the layer 1 in which the cured portion 2 (cured portion 2 which is buried in the layer 1 in the step) is buried (refer to Fig. 1H, Fig. 1I, Fig. 1O, and Fig. 1P), it is possible to more effectively prevent an occurrence of an unintended difference of elevation between the cured portion 2 buried in the layer 1 in the step and the second cured portion 2B. As a result, the dimensional accuracy of the three-dimensional structure 10 becomes particularly excellent.
  • the layer 1 of which the surface is flattened is formed using a squeegee as the flattening device M42.
  • the thickness of the layer 1 to be newly formed after formation of the cured product 6 is determined based on the height of the upper surface of the cured product 6. That is, the flattening device M42 is brought into contact with the upper surface of the cured product 6, and, based on the height (contact surface) at which the flattening device M42 is in contact with the cured product 6, the layer 1 having a predetermined thickness is formed.
  • a flattening device for example, a roller or the like
  • a squeegee may be used.
  • the composition 1' (in particular, particles 11) should not remain on the upper surface of the cured portion 2 buried in the step.
  • the thickness of the layer 1 formed in the step is the same as the thickness of the buried cured portion 2 (third cured portion 2C, the first cured portion 2A), however, the thickness of the layer 1 formed in the step may be smaller than the thickness of the buried cured portion 2 (third cured portion 2C, the first cured portion 2A).
  • the height adjustment of the flattening device M42 is performed so as to press the cured product 6 with a predetermined pressure force, and as a result, the stress applied to the flattening device M42 at a portion where the cured portion 2 or cured product 6 is not present becomes lower compared to the stress at a portion where the cured portion 2 or cured product 6 is present, and it is possible to make the height of the layer 1 formed by the flattening device M42 lower than that of the cured portion 2 buried in the step.
  • the thickness of the layer 1 formed in the step is not particularly limited, for example, the thickness of the layer 1 is preferably 20 micrometers to 500 micrometers, and more preferably 30 micrometers to 150 micrometers.
  • the viscosity of the layer forming composition 1' in the layer forming step is preferably 500 mPa*s to 1000000 mPa*s.
  • the viscosity refers to a value measured at 25 degrees centigrade using an E type viscometer (VISCONIC ELD manufactured by Tokyo Keiki Inc.).
  • the liquid 2' used in formation of the cured portion 2 (first cured portion 2A) is applied to a region including the surface (upper surface) of the layer 1 in a state of including the solvent 12 formed in the layer forming step (refer to Fig. 1E and Fig. 1L).
  • the embodiment has the first liquid applying step as a step of applying the liquid 2' to a region including a non-overlapping portion with the cured portion 2 (first cured portion 2A and the third cured portion 2C) when the layer 1 is seen in a plan view, of the surface of the layer 1 including the cured portion 2 (first cured portion 2A and the third cured portion 2C) buried (refer to Fig. 1E and Fig. 1L).
  • the first liquid applying step as a step of applying the liquid to a region including a non-overlapping portion with the cured portion (first cured portion and the third cured portion) when the layer is seen in a plan view, of the surface of the layer including the cured portion (first cured portion and the third cured portion) buried, effects as described above are more significantly exhibited.
  • the liquid 2' is applied by an ink jet method, and thus, it is possible to reproducibly apply the liquid 2' even in a case where the applying pattern of the liquid 2' has a fine shape. As a result, it is possible to make the dimensional accuracy of the finally obtained three-dimensional structure 10 particularly high.
  • the liquid 2' is also applied to the second region M412 (in the configuration in the figures, the upper surface of the cured product 6 formed in the third curing step) of the stage M41.
  • a predetermined curing treatment is performed on the liquid 2' (liquid 2' applied to a region including the surface (upper surface) of the layer 1 in a state of including the solvent 12) applied in the first liquid applying step, and as a result, the cured portion 2 (first cured portion 2A) is formed (refer to Fig. 1F and Fig. 1M).
  • a curing treatment as described above is also performed on the liquid 2' (in the configuration in the figures, the liquid 2' applied to the upper surface of the cured product 6 formed in the third curing step) applied to the second region M412 of the stage M41 in the first liquid applying step, and as a result, the cured product 6 is formed.
  • the solvent 12 is removed from the layer 1 (refer to Fig. 2A and Fig. 1N).
  • a space 4 in which the solvent 12 is not present is formed between the particles 11 configuring the layer 1.
  • the space 4 functions as an absorbing portion absorbing the liquid 2' in the subsequent second liquid applying step.
  • the step may be performed under any condition as long as the solvent 12 is removed from the layer 1, and for example, a heat treatment, a pressure reduction treatment, blowing, or the like can be performed in the step.
  • the heating temperature varies depending on the constituent material or the like (type or the like of the particles 11, the solvent 12, or the like) of the layer 1, for example, the heating temperature is preferably 30 degrees centigrade to 100 degrees centigrade, and more preferably 60 degrees centigrade to 95 degrees centigrade.
  • the liquid 2' used in formation of the cured portion 2 (second cured portion 2B) is applied, in the layer 1 in a state in which the solvent 12 is removed and the liquid 2' is penetrated into the layer 1 (refer to Fig. 1H and Fig. 1O).
  • the liquid 2' is applied by an ink jet method, and thus, it is possible to reproducibly apply the liquid 2' even in a case where the applying pattern of the liquid 2' has a fine shape. As a result, it is possible to make the dimensional accuracy of the finally obtained three-dimensional structure 10 particularly high.
  • the second curing step a predetermined curing treatment is performed on the liquid 2' (liquid 2' which penetrates into the inside (portion which is the space 4 between the particles 11) of the layer 1) applied in the second liquid applying step, and as a result, the cured portion 2 (second cured portion 2B) is formed (refer to Fig. 1I and Fig. 1P).
  • the bound portion 3 in which the particles 11 are bound by the cured portion 2 (second curing portion 2B). Since the bound portion 3 formed in this manner includes the particles 11 and the cured portion 2 (second cured portion 2B), the bound portion 3 has particularly excellent hardness and mechanical strength. Therefore, the finally obtained three-dimensional structure 10 has particularly excellent mechanical strength, unintended deformation thereof is more reliably prevented, and thus, the reliability thereof becomes higher. Unbound Particle Removing Step
  • the unbound particle removing step (refer to Fig. 1T) of removing particles (unbound particles) which are not bound by the cured portion 2, of the particles 11 configuring each layer 1 is performed. Thereby, the three-dimensional structure 10 is obtained.
  • Examples of the specific method of the step include a method of removing unbound particles with a brush or the like, a method of removing unbound particles by suction, a method of blowing a gas such as air, a method of applying a liquid such as water (for example, a method of immersing the layered product obtained in the same manner as described above in a liquid, and a method of spraying a liquid), and a method of applying vibration such as ultrasonic vibration.
  • two or more methods selected from these can be performed in combination. More specifically, a method of immersing into a liquid such as water after blowing a gas such as air, and a method of applying ultrasonic vibration in a state of being immersed into a liquid such as water are exemplified.
  • a method of applying a liquid including water is preferably employed with respect to the layered product obtained in the same manner as described above.
  • Figs. 2A to 2T are cross-sectional views schematically showing each step in the second embodiment of the method for manufacturing a three-dimensional structure according to the invention.
  • the second embodiment will be described while focusing on the difference from the embodiment described above, and the description of the same contents will not be repeated.
  • the method for manufacturing the three-dimensional structure 10 of the embodiment has the same steps as those in the embodiment described above, the thickness determining method of the layer 1 to be formed in the layer forming step is different from that in the embodiment described above.
  • the height (thickness) of the cured product 6 formed using the liquid 2' is measured by a height measuring device M7, and, based on the measurement result, the thickness of the layer 1 to be newly formed after formation of the cured product 6 is determined.
  • the flattening device M42 does not need to be brought into contact with the cured product 6, and thus, it is possible to prevent the unintended wear and deformation of the flattening device M42, and an effect in which extension of the life of the flattening device M42 is achieved, or the maintenance of the apparatus for manufacturing the three-dimensional structure 10 becomes easy is obtained.
  • the area of the cured product 6 is relatively small, it is possible to accurately measure the height (thickness) of the cured product 6, and it is possible to properly determine the thickness of the layer 1 to be newly formed.
  • Liquid Cured portion Forming Liquid
  • liquid (cured portion forming liquid) used in manufacturing the three-dimensional structure according to the invention will be described in detail.
  • the liquid (cured portion forming liquid) 2' includes at least a constituent (including a precursor) of the cured portion 2.
  • Curable Resin Material Polymerizable Compound
  • the liquid 2' includes a resin material (polymerizable compound) in which a curing reaction can be proceeded.
  • the second curing portion 2B it is possible to suitably function as a binder to bind the particles 11 to each other, and it is possible to make the mechanical strength and the stability of shape of the three-dimensional structure 10 excellent.
  • the heat resistance of the cured portion 2 becomes excellent, it is possible to more effectively prevent unintended deformation in the cured portion 2 which receives a cumulative thermal history due to the stacking, or unintended denaturation or deterioration of the material and it is possible to make the reliability of the three-dimensional structure 10 excellent.
  • the curable resin material examples include a thermosetting resin; various photocurable resins such as a visible light curable resin which is cured by light in the visible light region (photocurable resin in the narrow sense), a ultraviolet ray curable resin, and an infrared ray curable resin; and an X-ray curable resin, and one type or two or more types selected from these can be used singly or in combination.
  • various photocurable resins such as a visible light curable resin which is cured by light in the visible light region (photocurable resin in the narrow sense), a ultraviolet ray curable resin, and an infrared ray curable resin
  • an X-ray curable resin examples include a thermosetting resin; various photocurable resins such as a visible light curable resin which is cured by light in the visible light region (photocurable resin in the narrow sense), a ultraviolet ray curable resin, and an infrared ray curable resin; and an X-ray curable resin, and one type or two or more types selected from these
  • an ultraviolet ray curable resin (polymerizable compound) is preferable.
  • the ultraviolet ray curable resin polymerizable compound
  • a resin in which an addition polymerization or a ring-opening polymerization is initiated by radical species or cationic species generated from a photopolymerization initiator by irradiation of ultraviolet rays, and a polymer is generated is preferably used.
  • a radical, a cationic, an anionic, a metathesis, and a coordination polymerization can be exemplified.
  • a cationic, an anionic, a radical, a metathesis, and a coordination polymerization can be exemplified.
  • addition polymerizable compound examples include compounds having at least one ethylenically unsaturated double bond.
  • a compound having at least one terminal ethylenically unsaturated bond, and preferably two or more terminal ethylenically unsaturated bonds can be preferably used.
  • the ethylenically unsaturated polymerizable compound has a monofunctional polymerizable compound, a polyfunctional polymerizable compound, or a chemical form of mixture of these.
  • the monofunctional polymerizable compound include an unsaturated carboxylic acid (for example, acrylic acid, methacrylic acid, itaconic acid, crotonic acid, isocrotonic acid, and maleic acid), esters thereof, and amides.
  • esters of an unsaturated carboxylic acid and an aliphatic polyol compound, or an amides of an unsaturated carboxylic acid and an aliphatic polyamine compound are used.
  • the liquid 2' preferably includes an acryl-based polymerizable compound such as acrylic acid, methacrylic acid, or a derivative thereof (for example, an ester compound) as the polymerizable compound.
  • an acryl-based polymerizable compound such as acrylic acid, methacrylic acid, or a derivative thereof (for example, an ester compound) as the polymerizable compound.
  • a product of an addition reaction between unsaturated carboxylic acid esters or amides, which have a nucleophilic substituent such as a hydroxyl group, an amino group, or a mercapto group, and isocyanates or epoxies, a product of a dehydration condensation reaction between the above unsaturated carboxylic acid esters or amides and carboxylic acids, and the like also can be used.
  • a product of an addition reaction between unsaturated carboxylic acid esters or amides, which have an electrophilic substituent such as an isocyanate group or an epoxy group, and alcohols, amines, or thiols, and a product of a substitution reaction between unsaturated carboxylic acid esters or amides, which have a leaving substituent such as a halogen group or a tosyloxy group, and alcohols, amines, or thiols also can be used.
  • radical polymerizable compound which is an ester of an unsaturated carboxylic acid and an aliphatic polyol compound
  • (meth)acrylic acid ester is representatively exemplified, and any of a monofunctional compound and polyfunctional compound can be used.
  • a monofunctinoal (meth)acrylate examples include tolyloxyethyl (meth)acrylate, phenyloxyethyl (meth)acrylate, cyclohexyl (meth)acrylate, ethyl (meth)acrylate, methyl (meth)acrylate, isobornyl (meth)acrylate, and tetrahydrofurfuryl (meth)acrylate.
  • bifunctional (meth)acrylate examples include ethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, 1,3-butanediol di(meth)acrylate, tetramethylene glycol di(meth)acrylate, propylene glycol di(meth)acrylate, neopentyl glycol di(meth)acrylate, hexanediol di(meth)acrylate, 1,4-cyclohexanediol di(meth)acrylate, tetraethylene glycol di(meth)acrylate, pentaerythritol di(meth)acrylate, and dipentaerythritol di(meth)acrylate.
  • trifunctional (meth)acrylate examples include trimethylolpropane tri(meth)acrylate, trimethylolethane tri(meth)acrylate, alkylene oxide-modified tri(meth)acrylate of trimethylolpropane, pentaerythritol tri(meth)acrylate, dipentaerythritol tri(meth)acrylate, trimethylolpropane tri((meth)acryloyloxypropyl)ether, isocyanuric acid alkylene oxide-modified tri(meth)acrylate, propionic acid dipentaerythritol tri(meth)acrylate, tri((meth)acryloyloxyethyl) isocyanurate, hydroxypivalaldehyde-modified dimethylol propane tri(meth)acrylate, and sorbitol tri(meth)acrylate.
  • tetrafunctional (meth)acrylate examples include pentaerythritol tetra(meth)acrylate, sorbitol tetra(meth)acrylate, ditrimethylolpropane tetra(meth)acrylate, propionic acid dipentaerythritol tetra(meth)acrylate, and ethoxylated pentaerythritol tetra(meth)acrylate.
  • pentafunctional (meth)acrylate examples include sorbitol penta(meth)acrylate and dipentaerythritol penta(meth)acrylate.
  • hexafunctional (meth)acrylate examples include dipentaerythritol hexa(meth)acrylate, sorbitol hexa(meth)acrylate, alkylene oxide-modified hexa(meth)acrylate of phosphazene, and caprolactone-modified dipentaerythritol hexa(meth)acrylate.
  • polymerizable compounds other than (meth)acrylates examples include itaconic acid ester, crotonic acid ester, isocrotonic acid ester, and maleic acid ester.
  • Examples of the itaconic acid ester include ethylene glycol diitaconate, propylene glycol diitaconate, 1,3-butanediol diitaconate, 1,4-butanediol diitaconate, tetramethylene glycol diitaconate, pentaerythritol diitaconate, and sorbitol tetraitaconate.
  • crotonic acid ester examples include ethylene glycol dicrotonate, tetramethylene glycol dicrotonate, pentaerythritol dicrotonate, and sorbitol tetradicrotonate.
  • isocrotonic acid ester examples include ethylene glycol diisocrotonate, pentaerythritol diisocrotonate, and sorbitol tetraisocrotonate.
  • maleic acid ester examples include ethylene glycol dimaleate, triethylene glycol dimaleate, pentaerythritol dimaleate, and sorbitol tetramaleate.
  • amide monomer of an unsaturated carboxylic acid and an aliphatic amine compound examples include methylene bis-acrylamide, methylene bis-methacrylamide, 1,6-hexamethylene-bis-acrylamide, 1,6-hexamethylene-bis-methacrylamide, diethylenetriamine trisacrylamide, xylylene bis-acrylamide, and xylylene bis-methacrylamide.
  • a urethane-based addition polymerizable compound manufactured by an addition reaction between isocyanate and a hydroxyl group is also suitable, and as such a specific example thereof, a vinyl urethane compound containing two or more polymerizable vinyl groups in a molecule obtained by adding a vinyl monomer containing a hydroxyl group represented by the following formula (1) to a polyisocyanate compound having two or more isocyanate groups in a molecule can be exemplified.
  • a cationic ring-opening polymerizable compound having one or more cyclic ether groups such as an epoxy group or an oxetane group in a molecule can be suitably used as an ultraviolet ray curable resin (polymerizable compound).
  • curable compounds including a ring-opening polymerizable group can be exemplified, and among these, a heterocyclic group-containing curable compound is particularly preferable.
  • curable compounds include cyclic imino ethers such as epoxy derivatives, oxetane derivatives, tetrahydrofuran derivatives, cyclic lactone derivatives, cyclic carbonate derivatives, and oxazoline derivatives, and vinyl ethers, and among these, epoxy derivatives, oxetane derivatives, and vinyl ethers are preferable.
  • Examples of the preferred epoxy derivatives include monofunctional glycidyl ethers, polyfunctional glycidyl ethers, monofunctional alicyclic epoxies, and polyfunctional alicyclic epoxies.
  • glycidyl ethers examples include diglycidyl ethers (for example, ethylene glycol diglycidyl ether and bisphenol A diglycidyl ether), tri- or higher functional glycidyl ethers (for example, trimethylol ethane triglycidyl ether, trimethylol propane triglycidyl ether, glycerol triglycidyl ether, and triglycidyl trishydroxyethyl isocyanurate), tetra- or higher functional glycidyl ethers (for example, sorbitol tetraglycidyl ether, pentaerythritol tetraglycyl ether, polyglycidyl ether of a cresol novolac resin, and polyglycidyl ether of a phenolic novolac resin), alicyclic epoxies (for example, polycyclohexyl epoxy), alicycl
  • alicyclic epoxy derivatives can be preferably used as the polymerizable compound.
  • An "alicyclic epoxy group” refers to a substructure obtained by epoxidizing the double bond in the cycloalkene ring of a cyclopentene group, a cyclohexene group, or the like with a suitable oxidant such as hydrogen peroxide, peroxy acid, or the like.
  • alicyclic epoxy compound polyfunctional alicyclic epoxy compounds having two or more cyclohexene oxide groups or cyclopentene oxide groups in a molecule is preferable.
  • Specific examples of the alicyclic epoxy compound include 4-vinylcyclohexene dioxide, (3,4-epoxycyclohexyl)methyl-3,4-epoxycyclohexyl carboxylate, di(3,4-epoxycyclohexyl)adipate, di(3,4-epoxycyclohexylmethyl)adipate, bis(2,3-epoxycyclopentyl)ether, di(2,3-epoxy-6-methylcyclohexylmethyl)adipate, and dicyclopentadiene dioxide.
  • a glycidyl compound having an ordinary epoxy group which does not have an alicyclic structure in the molecule may be used alone or in combination with the above alicyclic epoxy compounds.
  • glycidyl compound As such an ordinary glycidyl compound, a glycidyl ether compound and a glycidyl ester compound can be exemplified, and the glycidyl ether compound is preferably used in combination.
  • the glycidyl ether compound examples include aromatic glycidyl ether compounds such as 1,3-bis(2,3-epoxypropyloxy)benzene, a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a phenol-novolac type epoxy resin, a cresol-novolac type epoxy resin, and a trisphenolmethane type epoxy resin, and aliphatic glycidyl ether compounds such as 1,4-butanediol glycidyl ether, glycerol triglycidyl ether, propylene glycol diglycidyl ether, and trimethylolpropane triglycidyl ether.
  • the glycidyl ester examples include glycidyl esters of a linolenic acid dimer.
  • a compound (hereinafter, simply referred to as an "oxetane compound") having an oxetanyl group which is a cyclic ether having a four-membered ring can be used.
  • An oxetanyl group-containing compound is a compound having one or more oxetanyl groups in a molecule.
  • the liquid 2' may include a silicone-based polymerizable compound (silicone-based resin obtained by polymerization) as the polymerizable compound.
  • the three-dimensional structure 10 which is configured of a rubber-like material having elasticity.
  • a three-dimensional structure having a movable portion and a deforming portion by elastic deformation.
  • the content of the curable resin material in the liquid 2' is preferably equal to or greater than 80% by mass, and more preferably equal to or greater than 85% by mass. Thereby, it is possible to make the mechanical strength or the like of the finally obtained three-dimensional structure 10 particularly excellent.
  • the liquid 2' may include components other than the components described above.
  • examples of such components include various colorants such as a pigment and a dye; a dispersant; a surfactant; a polymerization initiator; a polymerization accelerator; a solvent; a penetration enhancer; a wetting agent (humectant); a fixing agent; a fungicide; a preservative; an antioxidant; an ultraviolet absorbent; a chelating agent; a pH adjusting agent; a thickener; a filler; an aggregation preventing agent; and a defoamer.
  • various colorants such as a pigment and a dye; a dispersant; a surfactant; a polymerization initiator; a polymerization accelerator; a solvent; a penetration enhancer; a wetting agent (humectant); a fixing agent; a fungicide; a preservative; an antioxidant; an ultraviolet absorbent; a chelating agent; a pH adjusting agent; a
  • the liquid 2' includes a colorant
  • a pigment as a colorant, it is possible to make the light resistance of the liquid 2' and the three-dimensional structure 10 favorable.
  • a pigment as a colorant, it is possible to make the light resistance of the liquid 2' and the three-dimensional structure 10 favorable.
  • Both an inorganic pigment and an organic pigment can be used as the pigment.
  • the inorganic pigment examples include carbon blacks (C. I. Pigment Black 7) such as a furnace black, a lamp black, an acetylene black, and a channel black, iron oxide, and titanium oxide, and one type or two or more types selected from these can be used singly or in combination.
  • carbon blacks C. I. Pigment Black 7
  • titanium oxide is preferable in order to exhibit a preferred white color.
  • organic pigments examples include azo pigments such as an insoluble azo pigment, a condensed azo pigment, an azo lake, and a chelate azo pigment, polycyclic pigments such as a phthalocyanine pigment, a perylene and a perinone pigment, an anthraquinone pigment, a quinacridone pigment, a dioxane pigment, a thioindigo pigment, an isoindolinone pigment, and a quinophthalone pigment, a dye chelate (for example, a basic dye type chelate, an acidic dye type chelate, and the like), a dyeing lake (a basic dye type lake and an acidic dye type lake), a nitro pigment, a nitroso pigment, an aniline black, and a daylight fluorescent pigment, and one type or two or more types selected from these can be used singly or in combination.
  • azo pigments such as an insoluble azo pigment, a condensed azo pigment, an azo lake, and a
  • the average particle diameter of the pigment is preferably equal to or less than 300 nm, and more preferably 50 nm to 250 nm.
  • the average particle diameter refers to an average particle diameter based on volume, and for example, after a sample is added to methanol, the mixture is dispersed for 3 minutes with an ultrasonic wave disperser, and the average particle size of the obtained dispersion is measured using an aperture of 50 micrometers by a Coulter counter method particle size distribution measuring instrument (TA-II type manufactured by COULTER ELECTRONICS INS.).
  • examples of the dyes include an acidic dye, a direct dye, a reactive dye, and a basic dye, and one type or two or more types selected from these can be used singly or in combination.
  • the content of the colorant in the liquid 2' is preferably 1% by mass to 20% by mass. Thereby, particularly excellent concealing properties and color reproducibility are obtained.
  • the content of the titanium oxide in the liquid 2' is preferably 12% by mass to 18% by mass, and more preferably 14% by mass to 16% by mass. Thereby, particularly excellent concealing properties are obtained.
  • the liquid 2' includes a pigment
  • the liquid 2' further includes a dispersant
  • the dispersant include dispersants which are commonly used in the preparation of pigment dispersions such as a polymer dispersant.
  • polymer dispersant examples include dispersants containing one or more types among polyoxyalkylene polyalkylene polyamine, a vinyl-based polymer and copolymer, an acryl-based polymer and copolymer, polyester, polyamide, polyimide, polyurethane, an amino-based polymer, a silicon-containing polymer, a sulfur-containing polymer, a fluorine-containing polymer, and an epoxy resin, as a main component.
  • the liquid 2' includes a surfactant, it is possible to make the abrasion resistance of the three-dimensional structure 10 more favorable.
  • the surfactant is not particularly limited, and for example, silicone-based surfactants such as polyester-modified silicone or polyether-modified silicone can be used, and among these, polyether-modified polydimethyl siloxane or polyester-modified polydimethyl siloxane is preferably used.
  • the liquid 2' may include a solvent.
  • the viscosity of the liquid 2' it is possible to suitably adjust the viscosity of the liquid 2', and even in a case where the liquid 2' includes a component having a high viscosity, it is possible to make the discharge stability of the liquid 2' by an ink jet method excellent.
  • the solvent examples include (poly)alkylene glycol monoalkyl ethers such as ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, propylene glycol monomethyl ether, and propylene glycol monoethyl ether; acetic acid esters such as ethyl acetate, n-propyl acetate, iso-propyl acetate, n-butyl acetate, and iso-butyl acetate; aromatic hydrocarbons such as benzene, toluene, and xylene; ketones such as methyl ethyl ketone, acetone, methyl isobutyl ketone, ethyl-n-butyl ketone, diisopropyl ketone, and acetyl acetone; and alcohols such as ethanol, propanol, and butanol, and one type or two or more types selected from these can be used singly or in combination.
  • the viscosity of the liquid 2' is preferably 2 mPa . s to 30 mPa . s, and more preferably 5 mPa . s to 20 mPa . s. Thereby, it is possible to make the discharge stability of the liquid 2' by an ink jet method particularly excellent.
  • plural types of the liquid 2' may be used.
  • the liquid 2' used in the first liquid applying step liquid 2' used in formation of the first cured portion 2A
  • the liquid 2' used in the second liquid applying step liquid 2' used in formation of the second cured portion 2B
  • the liquid 2' used in the third liquid applying step liquid 2' used in formation of the third cured portion 2C
  • the liquid 2' used in the first liquid applying step liquid 2' used in formation of the first cured portion 2A
  • the liquid 2' used in the second liquid applying step liquid 2' used in formation of the second cured portion 2B
  • the liquid 2' used in the third liquid applying step liquid 2' used in formation of the third cured portion 2C
  • the liquid 2' (color ink) including a colorant and the liquid 2' (clear ink) not including a colorant may be used.
  • the liquid 2' including a colorant as the liquid 2' applied to a region that affects the color may be used, and regarding an appearance of the three-dimensional structure 10, the liquid 2' not including a colorant as the liquid 2' applied to a region that does not affect the color may be used.
  • plural types of the liquid 2' may be used in combination such that a region (coating layer) formed using the liquid 2' not including a colorant is provided to the outer surface of a region formed using the liquid 2' including a colorant.
  • plural types of the liquid 2' including colorants having different constitutions may be used. Thereby, by combination of these liquids 2', it is possible to widen a color reproduction region that can be expressed.
  • the liquid 2' In a case of using plural types of the liquid 2', it is preferable to use at least the liquid 2' having a cyan color, the liquid 2' having a magenta color, and the liquid 2' having a yellow color. Thereby, by combination of these liquids 2', it is possible to further widen a color reproduction region that can be expressed.
  • the liquid 2' having a white color and other liquid 2' having a color in combination for example, the following effect is obtained. That is, it is possible to make the finally obtained three-dimensional structure 10 have a first region where the liquid 2' having a white color is applied and a region (second region) where the liquid 2' having a color other than a white color is applied, and which is overlapped with the first region and provided on the outer surface than the first region. Thereby, the first region where the liquid 2' having a white color is applied can exhibit a concealing properties, and it is possible to further increase color saturation of the three-dimensional structure 10.
  • the composition (layer forming composition) 1' includes the particles 11 as a filler, and the solvent 12 as a dispersion medium dispersing the particles 11.
  • the layer forming composition 1' By using the layer forming composition 1', it is possible to make the mechanical strength or the like of the finally obtained three-dimensional structure 10 particularly excellent, it is possible to make the fluidity of the composition 1' excellent and to also effectively prevent aggregation or the like of the particles 11, and it is possible to make ease of handling (handleability) of the composition 1' during manufacture particularly excellent.
  • the layer forming composition 1' includes a plurality of particles 11.
  • the particle 11 has preferably a high hardness.
  • the hardness of the particles 11 can be determined, for example, by particle compression strength evaluation using MCT-210 (manufactured by Shimadzu Corporation).
  • the particles 11 are preferably porous particles having pores which open to the outside and subjected to a hydrophobization treatment.
  • the curable resin material configuring the liquid 2' or the reaction product (hereinafter, also collectively simply referred to as "resin material”) suitably penetrate into the pores when the three-dimensional structure 10 is manufactured (in the second liquid applying step), and an anchoring effect is exhibited.
  • resin material also collectively simply referred to as "resin material”
  • the resin material configuring the liquid 2' enters into the space of the particles 11, it is possible to effectively prevent unintended wet-spreading of the liquid 2'. As a result, it is possible to make the dimensional accuracy of the finally obtained three-dimensional structure 10 higher.
  • Examples of the constituent material of the particles 11 include an inorganic material, an organic material, and a complex of these.
  • Examples of the inorganic material configuring the particles 11 include various metals and metal compounds.
  • Examples of the metal compound include various metal oxides such as silica, alumina, titanium oxide, zinc oxide, zirconium oxide, tin oxide, magnesium oxide, and potassium titanate; various metal hydroxides such as magnesium hydroxide, aluminum hydroxide, and calcium hydroxide; various metal nitrides such as silicon nitride, titanium nitride, and aluminum nitride; various metal carbides such as silicon carbide and titanium carbide; various metal sulfides such as zinc sulfide; various metal carbonates such as calcium carbonate and magnesium carbonate; various metal sulfates such as calcium sulfate and magnesium sulfate; various metal silicates such as calcium silicate and magnesium silicate; various metal phosphates such as calcium phosphate; and various metal borates such as aluminum borate and magnesium borate, or composite compounds of these.
  • synthetic resins and natural polymers can be exemplified, and more specific examples thereof include a polyethylene resin; polypropylene; polyethylene oxide; polypropylene oxide, polyethylene imine; polystyrene; polyurethane; polyurea; polyester; a silicone resin; an acrylic silicone resin; polymers having (meth)acrylic acid ester as a constituent monomer such as polymethyl methacrylate; cross polymers having (meth)acrylic acid ester as a constituent monomer such as methyl methacrylate cross polymer (ethylene acrylic acid copolymer resin or the like); polyamide resins such as Nylon 12, Nylon 6, and copolymer nylon; polyimide; carboxymethyl cellulose; gelatin; starch; chitin; and chitosan.
  • polyethylene resin polypropylene
  • polyethylene oxide polypropylene oxide
  • polyethylene imine polystyrene
  • polyurethane polyurea
  • polyester a silicone resin
  • an acrylic silicone resin polymers having (meth)acrylic
  • the particles 11 are preferably configured of a metal oxide, and more preferably configured of silica.
  • silica has also excellent fluidity, silica is useful for forming a layer having higher thickness uniformity, and silica is also advantageous from the viewpoint of making the productivity and dimensional accuracy of the three-dimensional structure particularly excellent.
  • the particles 11 may be subjected to a surface treatment such as a hydrophobization treatment.
  • a surface treatment such as a hydrophobization treatment.
  • any treatment may be used as long as it increases hydrophobicity of the particles (base particles), and it is preferable to introduce a hydrocarbon group.
  • a silane compound including a silyl group is preferable.
  • Specific examples of the compound which can be used in the hydrophobization treatment include hexamethyldisilazane, dimethyl dimethoxysilane, diethyl diethoxysilane, 1-propenylmethyl dichlorosilane, propyldimethyl chlorosilane, propylmethyl dichlorosilane, propyl trichlorosilane, propyl triethoxysilane, propyl trimethoxysilane, styrylethyl trimethoxysilane, tetradecyl trichlorosilane, 3-thiocyanatopropyl triethoxysilane, p-tolyldimethyl chlorosilane, p-tolylmethyl dichlorosilane, p-tolyl trichlorosilane, p-tolyl trimethoxysi
  • hexamethyl disilazane is preferably used in the hydrophobization treatment.
  • hydrophobicity of the particles 11 it is possible to further increase hydrophobicity of the particles 11.
  • the hydrophobization treatment using a silane compound is performed in a liquid phase, by immersing the particles (base particles) to be subjected to the hydrophobization treatment in the liquid including the silane compound, it is possible to make a suitable desired reaction proceed, and it is possible to form a chemical adsorption film of the silane compound.
  • the hydrophobization treatment using a silane compound is performed in a gas phase, by exposing the particles (base particles) to be subjected to the hydrophobization treatment to the vapor of the silane compound, it is possible to make a suitable desired reaction proceed, and it is possible to form a chemical adsorption film of the silane compound.
  • the average particle diameter of the particles 11 is not particularly limited, the average particle diameter of the particles 11 is preferably 1 micrometer to 25 micrometers, and more preferably 1 micrometer to 15 micrometers.
  • D max of the particles 11 is preferably 3 micrometers to 40 micrometers, and more preferably 5 micrometers to 30 micrometers.
  • the porosity of the particles 11 is preferably equal to or greater than 50%, and more preferably 55% to 90%.
  • the particles can have sufficient space (pores) into which the resin material (binder) enters, and it is possible to make the mechanical strength of the particles 11 excellent, and as a result, it is possible to make the mechanical strength of the three-dimensional structure 10 having the bound portion 3 obtained by penetration of the resin material into pores particularly excellent.
  • the porosity of the particles 11 refers to a proportion (volume ratio) of pores which are present in the inside of the particles 11, with respect to the apparent volume of the particles 11, and when the density of the particles 11 is defined as rho [g/cm 3 ] and the true density of the constituent material of the particles 11 is defined as rho0 [g/cm 3 ], the porosity of the particles 11 is a value represented by ⁇ (rho0 - rho)/rho0 ⁇ x 100.
  • the average pore diameter (fine pore diameter) of the particles 11 is preferably equal to or greater than 10 nm, and more preferably 50 nm to 300 nm.
  • the mechanical strength of the finally obtained three-dimensional structure 10 is possible to make the mechanical strength of the finally obtained three-dimensional structure 10 particularly excellent.
  • the liquid 2' (color ink) including a pigment in manufacturing the three-dimensional structure 10 it is possible to suitably hold the pigment in pores of the particles 11. Therefore, it is possible to prevent unwanted diffusion of the pigment, and it is possible to more reliably form a high-definition image.
  • the particles 11 may have any shape, the particles 11 preferably have a spherical shape. Thereby, it is possible to make the fluidity of the layer forming composition 1' particularly excellent and make the productivity of the three-dimensional structure 10 particularly excellent, and it is possible to more effectively prevent an occurrence of unintended unevenness in the three-dimensional structure 10 to be manufactured and make the dimensional accuracy of the three-dimensional structure 10 particularly excellent.
  • the layer forming composition 1' may include plural types of particles 11.
  • the content of the particles 11 in the layer forming composition 1' is preferably 8% by mass to 91% by mass, and more preferably 10% by mass to 53% by mass.
  • the layer forming composition 1' includes the solvent 12.
  • Examples of the solvent configuring the layer forming composition 1' include water; alcoholic solvents such as methanol, ethanol, and isopropanol; ketone-based solvents such as methyl ethyl ketone and acetone; glycol ether-based solvents such as ethylene glycol monoethyl ether and ethylene glycol monobutyl ether, glycol ether acetate-based solvents such as propylene glycol 1-monomethyl ether 2-acetate and propylene glycol 1-monoethyl ether 2-acetate; polyethylene glycol, and polypropylene glycol, and one type or two or more types selected from these can be used singly or in combination.
  • alcoholic solvents such as methanol, ethanol, and isopropanol
  • ketone-based solvents such as methyl ethyl ketone and acetone
  • glycol ether-based solvents such as ethylene glycol monoethyl ether and ethylene glycol monobutyl ether
  • the layer forming composition 1' preferably includes an aqueous solvent, and more preferably includes water.
  • the liquid 2' used in formation of the first cured portion 2A includes a polymerizable compound (in particular, an acryl-based polymerizable compound or a silicone-based polymerizable compound) as described above, it is possible to more effectively prevent unintended penetration of the liquid 2' into the layer 1 (layer 1 including the solvent 12), it is possible to more reliably form the first cured portion 2A having a desired shape, and it is possible to make the dimensional accuracy and the reliability of the three-dimensional structure 10 particularly excellent.
  • a polymerizable compound in particular, an acryl-based polymerizable compound or a silicone-based polymerizable compound
  • the layer forming composition 1' includes a water-soluble resin as a binder described below in detail, it is possible to make the water-soluble resin be in a more suitable dissolved state in the layer forming composition 1', and effects due to including a binder (water-soluble resin) as described below in detail are more effectively exhibited.
  • the aqueous solvent is not limited as long as it has a high solubility in water, and specifically, for example, an aqueous solvent having a solubility (mass dissolvable in 100g of water) of equal to or greater than 30 [g/100 g water] in water at 25 degrees centigrade is preferable, and an aqueous solvent having a solubility of equal to or greater than 50 [g/100 g water] in water at 25 degrees centigrade is more preferable.
  • the content of the solvent 12 in the layer forming composition 1' is preferably 9% by mass to 92% by mass, and more preferably 29% by mass to 89% by mass.
  • the content of the water in the layer forming composition 1' is preferably 18% by mass to 92% by mass, and more preferably 47% by mass to 90% by mass.
  • Binder The layer forming composition 1' may include a plurality of particles 11, the solvent 12, and a binder.
  • the layer 1 in particular, the layer 1 in a state in which the solvent 12 is removed
  • the layer forming composition 1' it is possible to suitably bind (temporarily fix) a plurality of particles 11, and it is possible to effectively prevent unintended scattering of the particles 11.
  • the layer forming composition 1' includes a binder
  • the fluidity of the layer forming composition 1' particularly favorable, and it is possible to more effectively prevent unintended variations in the thickness of the layer 1 formed using the layer forming composition 1'.
  • the layer 1 in a state in which the solvent 12 is removed is formed, it is possible to attach the binder to the particles 11 with higher uniformity over the entire layer 1, and it is possible to more effectively prevent an occurrence of unintended constitution unevenness. For this reason, it is possible to more effectively prevent an occurrence of unintended variations in the mechanical strength at each portion of the finally obtained three-dimensional structure 10, and it is possible to further increase the reliability of the three-dimensional structure 10.
  • the binder may have a function of temporarily fixing the plurality of particles 11 in the layer 1 (in particular, the layer 1 in a state in which the solvent 12 is removed) formed using the layer forming composition 1', it is possible to suitably use a water-soluble resin.
  • the layer forming composition 1' includes an aqueous solvent (in particular, water) as the solvent 12 by including a water-soluble resin
  • a aqueous solvent in particular, water
  • the binder water-soluble resin
  • the productivity of the three-dimensional structure 10 particularly excellent.
  • the water-soluble resin is not limited as long as at least a part thereof is soluble in an aqueous solvent, and for example, a water-soluble resin having a solubility of equal to or greater than 5 [g/100 g water] in water at 25 degrees centigrade is preferable, and a water-soluble resin having a solubility of equal to or greater than 10 [g/100 g water] in water at 25 degrees centigrade is more preferable.
  • water-soluble resin examples include synthetic polymers such as polyvinyl alcohol (PVA), polyvinyl pyrrolidone (PVP), polycaprolactonediol, sodium polyacrylate, polyacryl amide, modified polyamide, polyethylene imine, polyethylene oxide, and a random copolymer of ethylene oxide and propylene oxide, natural polymers such as cornstarch, mannan, pectin, agar, alginic acid, dextran, glues, and gelatin, and semi-synthetic polymers such as carboxymethyl cellulose, hydroxyethyl cellulose, oxidized starch, and modified starch, and one type or two or more types selected from these can be used singly or in combination.
  • synthetic polymers such as polyvinyl alcohol (PVA), polyvinyl pyrrolidone (PVP), polycaprolactonediol, sodium polyacrylate, polyacryl amide, modified polyamide, polyethylene imine, polyethylene oxide, and a random copolymer of
  • water-soluble resin product examples include methyl cellulose (manufactured by Shin-Etsu Chemicals Co., Ltd., Metolose SM-15), hydroxyethyl cellulose (manufactured by Fuji Chemical Industry Co., Ltd., AL-15), hydroxypropyl cellulose (manufactured by Nippon Soda Co., Ltd., HPC-M), carboxymethyl cellulose (Nichirin Chemical Co., Ltd., CMC-30), sodium (I) starch phosphate (manufactured by Matsutani Chemical Industry Co., Ltd., Hoster 5100), polyvinyl pyrrolidone (manufactured by Tokyo Chemical Industry Co., Ltd., PVP K-90), a methyl vinyl ether/maleic anhydride copolymer (manufactured by GAF Gantrez, AN-139), polyacryl amide (manufactured by Wako Pure Chemical Industries, Ltd.), modified polyamide (modified nylon) (manufactured by
  • the water-soluble resin as a binder is polyvinyl alcohol
  • the mechanical strength of the three-dimensional structure 10 particularly excellent.
  • by adjusting the saponification degree and the polymerization degree it is possible to more suitably control characteristics (for example, water solubility and water resistance) of the binder or characteristics (for example, viscosity, fixing force of the particles 11, and wettability) of the layer forming composition 1'. Therefore, it is possible to more suitably cope with according to manufacture of the various three-dimensional structures 10.
  • polyvinyl alcohol is inexpensive and a supply thereof is stable. Therefore, it is possible to manufacture the stable three-dimensional structure 10 while reducing the production cost.
  • the saponification degree of the polyvinyl alcohol is preferably 85 to 90.
  • the saponification degree of the polyvinyl alcohol is preferably 85 to 90.
  • the polymerization degree of the polyvinyl alcohol is preferably 300 to 1000.
  • the water-soluble resin as a binder is polyvinyl pyrrolidone (PVP)
  • PVP polyvinyl pyrrolidone
  • polyvinyl pyrrolidone shows high solubility in various organic solvents, in a case where the layer forming composition 1' includes an organic solvent, it is possible to make the fluidity of the layer forming composition 1' excellent, it is possible to suitably form the layer 1' in which unintentional variations in the thickness are more effectively prevented, and it is possible to make the dimensional accuracy of the finally obtained three-dimensional structure 10 particularly excellent. Since polyvinyl pyrrolidone shows high solubility also in an aqueous solvent (in particular, water), in the unbound particle removing step (after forming ends), it is possible to easily and reliably remove the particles unbound by a resin material (binder) of the particles 11 configuring each layer 1. In addition, since polyvinyl pyrrolidone has excellent affinity with various colorants, in the case of using the liquid 2' including a colorant in the second liquid applying step, it is possible to effectively prevent the colorant from being unintentionally spread.
  • the weight average molecular weight of the polyvinyl pyrrolidone is preferably 10000 to 1700000, and more preferably 30000 to 1500000. Thereby, it is possible to more effectively exhibit the function described above.
  • the weight average molecular weight of the polycaprolactonediol is preferably 10000 to 1700000, and more preferably 30000 to 1500000. Thereby, it is possible to more effectively exhibit the function described above.
  • the binder is preferably in a liquid state (for example, a dissolved state or a molten state) in the film forming step. Thereby, it is possible to easily and reliably further increase uniformity in the thickness of the layer 1 formed using the layer forming composition 1'.
  • the content of the binder in the layer forming composition 1' is preferably 0.5% by mass to 25% by mass, and more preferably 1.0% by mass to 10% by mass.
  • the layer forming composition may include components other than the components described above.
  • examples of such components include a polymerization initiator; a polymerization accelerator; a penetration enhancer; a wetting agent (humectant); a fixing agent; a fungicide; a preservative; an antioxidant; a ultraviolet absorbent; a chelating agent; and a pH adjusting agent.
  • Fig. 3 is a cross-sectional view schematically showing a preferred embodiment of the three-dimensional structure manufacturing apparatus according to the invention.
  • a three-dimensional structure manufacturing apparatus M100 is an apparatus for manufacturing the three-dimensional structure 10 by repeatedly forming and stacking the layers 1 using the layer forming composition 1'.
  • the three-dimensional structure manufacturing apparatus M100 is an apparatus for manufacturing the three-dimensional structure 10 by performing the method for manufacturing a three-dimensional structure according to the invention as described above.
  • the three-dimensional structure manufacturing apparatus M100 has a control portion M2, a composition supply portion M3 which accommodates the layer forming composition 1', a layer forming portion M4 which forms the layer 1 using the layer forming composition 1' supplied from the composition supply portion M3, a liquid discharge portion (liquid applying device) M5 which discharges the liquid 2' to the layer 1, an energy ray irradiation device (curing device) M6 which applies an energy rays to cure the liquid 2', and a height measuring device M7 which measures the height of the cured product 6 formed using the liquid 2'.
  • a control portion M2 which accommodates the layer forming composition 1'
  • a layer forming portion M4 which forms the layer 1 using the layer forming composition 1' supplied from the composition supply portion M3 supplied from the composition supply portion M3, a liquid discharge portion (liquid applying device) M5 which discharges the liquid 2' to the layer 1, an energy ray irradiation device (curing device) M6 which applies an energy rays to cure the liquid 2', and
  • the control portion M2 has a computer M21 and a drive control portion M22.
  • the computer M21 is a general desk type computer which is configured to equip a CPU and a memory therein.
  • the computer M21 converts the shape of the three-dimensional structure 10 to model data, and a cross-sectional data (slice data) obtained by slicing the model data into several parallel layers of a thin cross-sectional body is output to the drive control portion M22.
  • the height of the upper surface of the cured product 6 is measured by the height measuring device M7 descried below, and in the case of adjusting the thickness of the layer 1 based on the height, rewriting (correction and revision) of the cross-sectional data (slice data) is performed based on the thickness of the layer 1.
  • the drive control portion M22 functions as a control device which drives the layer forming portion M4, the liquid discharge portion M5, the energy ray irradiation device M6, the height measuring device M7, or the like, respectively. Specifically, for example, the drive control portion M22 controls a discharge pattern or discharge amount of the liquid 2' by the liquid discharge portion M5, the supply amount of the layer forming composition 1' from the composition supply portion M3, and the extent of descent of the stage (lifting stage) M41.
  • the composition supply portion M3 is moved by the instructions from the drive control portion M22, and configured such that the layer forming composition 1' contained therein is supplied to the stage M41.
  • the layer forming portion M4 has, the stage (lifting stage) M41 to which the layer forming composition 1' is supplied and supports the layer 1 formed of the layer forming composition 1', the flattening device (squeegee) M42 which forms the layer 1 while flattening the layer forming composition 1' held on the stage M41, a guide rail M43 which regulates the operation of the flattening device M42, and a frame body M45 which surrounds the lifting stage M41 and is provided so as to be in close contact with the lifting stage M41.
  • the stage (lifting stage) M41 to which the layer forming composition 1' is supplied and supports the layer 1 formed of the layer forming composition 1'
  • the flattening device (squeegee) M42 which forms the layer 1 while flattening the layer forming composition 1' held on the stage M41
  • a guide rail M43 which regulates the operation of the flattening device M42
  • a frame body M45 which surrounds the lifting stage M41 and is provided so as to be in close contact
  • the lifting stage M41 descends sequentially by only a predetermined extent by the instructions from the drive control portion M22 when forming a new layer 1 on the layer 1 formed previously.
  • the extent of descent of the lifting stage M41 and the height of the flattening device M42 described below in detail the thickness of the layer 1 newly formed is defined.
  • the stage M41 has the flat surface (a portion to which the layer forming composition 1' and the liquid 2' are applied, a portion including the first region M411 and the second region M412). Thereby, it is possible to easily and reliably form the layer 1 having high thickness uniformity. In addition, on the basis of the height of the upper surface of the cured product 6, it is possible to suitably adjust the thickness of the layer 1 newly formed.
  • the stage M41 is preferably configured of a material having high strength.
  • Examples of the constituent material of the stage M41 include various metal materials such as stainless steel.
  • a surface treatment may be performed on the surface (a portion to which the layer forming composition 1' and the liquid 2' are applied, a portion including the first region M411 and the second region M412) of the stage M41.
  • the material used in the surface treatment of the surface of the stage M41 include fluorine-based resins such as polytetrafluoroethylene.
  • the squeegee as the flattening device M42 has a long shape extending in the X direction, and is equipped with a blade having a blade-like shape in which the lower tip is sharp.
  • the layer 1 formed by flattening of the layer forming composition 1' is suitably adjusted as necessary based on information such as the height of the upper surface of the cured product 6 by the height measuring device M7, by the flattening device M42, it is possible to prevent the constituent (for example, the particles 11) of the layer forming composition 1' from unintentionally remaining on the upper surface of the cured portion 2 at the time when the layer forming step ends.
  • the blade may equipped with a vibration mechanism (not shown) which applies fine vibration to the blade such that diffusion of the layer forming composition 1' by the flattening device (squeegee) M42 is smoothly performed.
  • the three-dimensional structure manufacturing apparatus M100 may be equipped with a stress detecting device (not shown) which detects stress applied to the flattening device M42 when the flattening device M42 is in contact with the upper surface of the cured product 6 formed at the second region M412 of the stage M41.
  • a stress detecting device not shown
  • bringing the flattening device M42 into contact with the cured product 6 can be more suitably performed by relatively moving the stage M41 and the flattening device M42 in the Z direction, and for example, it may be performed by moving the flattening device M42 in the downward direction, or may be performed by moving the stage M41 in the upward direction.
  • the liquid discharge portion (liquid applying device) M5 discharges the liquid 2' by an ink jet method.
  • a liquid discharge portion (liquid applying device) M5 By equipping such a liquid discharge portion (liquid applying device) M5, it is possible to apply the liquid 2' in fine patterns, and it is even possible to manufacture the three-dimensional structure 10 having a fine configuration with particularly excellent productivity.
  • a piezo system or a system for discharging the liquid 2' by bubbles generated by heating the liquid 2' can be used, and from the viewpoint of the difficulty in changing in quality of the constituent of the liquid 2', the piezo system is preferable.
  • liquid discharge portion (liquid applying device) M5 a pattern to be formed or the amount of the liquid 2' to be applied is controlled by the instructions from the drive control portion M22.
  • the discharge pattern, the discharge amount, or the like of the liquid 2' by the liquid discharge portion (liquid applying device) M5 is determined based on the slice data.
  • the liquid 2' includes a colorant, it is possible to reliably obtain a desired color, and it is possible to reliably prevent an occurrence of an unintentional color change and unintentional collapse of the color balance, due to the change in the thickness of the layer 1.
  • the energy ray irradiation device (curing device) M6 applies energy rays to cure the liquid 2' applied.
  • the type of energy rays that the energy ray irradiation device M6 applies varies depending on the constituent materials of the liquid 2', and examples thereof include ultraviolet rays, visible rays, infrared rays, X-rays, gamma-rays, an electron beam, and an ion beam. Among these, ultraviolet rays are preferably used from the viewpoint of cost and productivity of the three-dimensional structure 10.
  • the height measuring device M7 measures the height of the upper surface of the cured product 6. Information on the height of the upper surface of the cured product 6 is transmitted to the control protion M2 from the height measuring device M7, and is used in adjusting the thickness of the layer 1 to be formed and the relative height of the flattening device M42.
  • the height measuring device M7 determines the height of the cured product 6 by determining the focal length from the upper direction of the cured product 6. Since it is possible to measure the height of the cured product 6 without moving the height measuring device M7 by such a configuration, it is possible to shorten the time required for measuring the height of the cured product 6, and it is possible to make the productivity of the three-dimensional structure 10 particularly excellent.
  • the three-dimensional structure according to the invention is manufactured using the manufacturing method according to the invention. Thereby, it is possible to provide a three-dimensional structure which has the dimensional accuracy and the mechanical strength.
  • Use of the three-dimensional structure according to the invention is not particularly limited, and examples thereof include items for appreciation and articles on exhibition such as a doll and a figure; and medical devices such as an implant.
  • the three-dimensional structure according to the invention may be applied to any of a prototype, mass-produced products, and tailor made products.
  • a cured portion is formed, however, the embodiments may have a layer in which a cured portion is not formed.
  • a layer formed just on the stage may be functioned as a sacrificial layer without forming a cured portion thereon.
  • the cured product used in determining the thickness of a layer may be a cured product formed at the first region, in particular, a part of an entity portion of the three-dimensional structure.
  • the height of the upper surface of a cured product used in determining the thickness of a layer is determined by an observation from the upper surface of the cured product
  • the height of the upper surface of a cured product may be determined by an observation from the side surface of the cured product.
  • the height measuring device may be movable (for example, movable in the XY direction of the stage).
  • the layer forming composition may include at least a plurality of particles, or may not include a solvent.
  • each area of the plurality of cured products to be stacked decreases sequentially towards the upper side
  • the layered product with a plurality of cured products formed by being stacked may have a shape such as a pyramid shape or the like. Even in such a case, the same effects as described above are obtained.
  • the three-dimensional structure manufacturing apparatus may be equipped with a recovery mechanism not shown for recovering the composition unused in formation of a layer of the composition supplied from the composition supply portion.
  • a recovery mechanism not shown for recovering the composition unused in formation of a layer of the composition supplied from the composition supply portion.
  • the three-dimensional structure manufacturing apparatus according to the invention may be equipped with a recovery mechanism for recovering the composition removed in the unbound particle removing step.
  • the series of steps repeatedly performed may be different in each cycle, and for example, the series of steps repeatedly performed may have a cycle in which the first liquid applying step and the first curing step of the above steps are omitted, or may have a cycle in which the second liquid applying step and the second curing step of the above steps are omitted.
  • the curing treatment performed for formation of each curing portion may not repeatedly performed each time a pattern corresponding to each curing portion is formed, and may be collectively performed after a layered product in which uncured patterns are provided on the plurality of layers is formed.
  • a pretreatment step, an intermediate treatment step, or a post-treatment step may be performed, as necessary.
  • Examples of the pretreatment step include a cleaning step of the stage or the like.
  • Examples of the post-treatment step include a cleaning step, a shape adjusting step of performing deburring or the like, a coloring step, a coating layer forming step, and a resin material curing completion step of performing a light irradiation treatment or a heating treatment to reliably cure an uncured resin material.

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Abstract

L'invention porte sur un procédé de fabrication d'une structure tridimensionnelle par répétition d'un traitement de formation d'une couche et de déversement d'un liquide sur la couche, le procédé comprenant les étapes suivantes : la formation d'une couche dont l'épaisseur est prédéfinie à l'aide d'une composition de formation de couche comprenant des particules ; l'application de liquide sur la couche ; le durcissement d'une partie durcie par durcissement du liquide, une épaisseur de la couche à former nouvellement après la formation du produit durci étant déterminée sur la base de la hauteur d'une surface supérieure d'un produit durci, formé à l'aide du liquide.
PCT/JP2015/005357 2014-10-30 2015-10-26 Procédé de fabrication de structure tridimensionnelle, appareil de fabrication de structure tridimensionnelle et structure tridimensionnelle Ceased WO2016067584A1 (fr)

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US10347655B2 (en) 2016-01-22 2019-07-09 Kabushiki Kaisha Toshiba Semiconductor switch
US11453161B2 (en) 2016-10-27 2022-09-27 Bridgestone Americas Tire Operations, Llc Processes for producing cured polymeric products by additive manufacturing

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CN106853687B (zh) * 2017-01-09 2019-06-11 北京彩韵数码科技有限公司 一种自动修平的彩色喷墨3d打印方法

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JP2000167938A (ja) * 1998-12-04 2000-06-20 Matsushita Electric Works Ltd 三次元形状物の形成方法
JP2010240843A (ja) * 2009-04-01 2010-10-28 Seiko Epson Corp 立体造形方法および立体造形装置
JP2012030389A (ja) * 2010-07-28 2012-02-16 Seiko Epson Corp 造形方法
JP2013067121A (ja) * 2011-09-22 2013-04-18 Keyence Corp 三次元造形装置及び三次元造形方法
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JPH02175134A (ja) * 1988-10-13 1990-07-06 Matsushita Electric Works Ltd 三次元形状の形成方法および装置
JP2000167938A (ja) * 1998-12-04 2000-06-20 Matsushita Electric Works Ltd 三次元形状物の形成方法
JP2010240843A (ja) * 2009-04-01 2010-10-28 Seiko Epson Corp 立体造形方法および立体造形装置
JP2012030389A (ja) * 2010-07-28 2012-02-16 Seiko Epson Corp 造形方法
JP2013067121A (ja) * 2011-09-22 2013-04-18 Keyence Corp 三次元造形装置及び三次元造形方法
JP2013067119A (ja) * 2011-09-22 2013-04-18 Keyence Corp 三次元造形装置

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10347655B2 (en) 2016-01-22 2019-07-09 Kabushiki Kaisha Toshiba Semiconductor switch
US11453161B2 (en) 2016-10-27 2022-09-27 Bridgestone Americas Tire Operations, Llc Processes for producing cured polymeric products by additive manufacturing

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