FIG. 5 is a descriptive view diagrammatically showing that the three-dimensionally shaping apparatus 100 shapes a three-dimensionally shaped object MD. In the three-dimensionally shaping apparatus 100, a shaping material M3 and a support material M4 are produced, as described above. The controller 300 causes the shaping material M3 to be discharged from the first nozzle 61a with the distance between the shaping surface 211 of the stage 210 and the first nozzle 61a maintained while changing the position of the first nozzle 61a with respect to the stage 210 in the direction along the shaping surface 211 of the stage 210. The controller 300 further causes the support material M4 to be discharged from the second nozzle 61b with the distance between the shaping surface 211 of the stage 210 and the second nozzle 61b (not shown) maintained while changing the position of the second nozzle 61b with respect to the stage 210 in the direction along the shaping surface 211 of the stage 210. The material discharged from the nozzle 61 is continuously deposited in the direction in which the nozzle 61 is moved.

The controller 300 forms layers ML by repeating the movement of the nozzle 61. One layer ML is made of only the shaping material M3 or both the shaping material M3 and the support material M4. After forming one layer ML, the controller 300 moves the position of the nozzle 61 with respect to the stage 210 in the Z direction. The controller 300 then shapes a shaped object MD1 and a support structure MD2 by further stacking another layer ML on the layer ML that has been formed. Hereinafter, the lowermost layer ML is referred to as a first layer, and the n-th (n is natural number) layer ML counted from the first layer is referred to as an n-th layer.

For example, when the operation of discharging the shaping material M3 from the first nozzle 61a and the operation of discharging the support material M4 from the second nozzle 61b are switched from one to the other during the formation of one layer ML, when the nozzle 61 is moved in the Z direction after the operation of shaping a layer ML corresponding to one layer is completed, or when each layer ML has multiple independent shaped regions, the controller 300 may temporarily interrupt the operation of discharging the plasticized material from the nozzle 61. In this case, the discharge controller 70 closes the channel 65 to stop discharging the plasticized material via the nozzle opening 62, and causes the suction section 72 to temporarily suction the plasticized material in the nozzle 61. After changing the position of the nozzle 61, the controller 300 causes the discharge controller 70 to open the channel 65 while discharging the plasticized material in the suction section 72, and restarts depositing the plasticized material at the changed position of the nozzle 61.

The shaped object MD1 has a contour region ZD1 and an inner region ZD2. The contour region ZD1 is a region that constitutes the contour of the shaped object MD1, and means a portion located at the contour of the shaped object MD1 having gone through the shaping operation. The inner region ZD2 is a region inside the contour region ZD1, and means a portion located inside the shaped object MD1 having gone through the shaping operation. The inner region ZD2 is also referred to as infilling. In FIG. 5, the contour region ZD1 is hatched with oblique lines to clearly show the contour region ZD1.

FIG. 6 is a descriptive view showing a schematic configuration of the information processing apparatus 400. The information processing apparatus 400 is configured as a computer including a CPU 410, a memory 420, a storage 430, a communication interface 440, and an input/output interface 450, which are coupled to each other via a bus 460. An input device 470 such as a keyboard and a mouse and a display device 480 such as a liquid crystal display are coupled to the input/output interface 450. The information processing apparatus 400 is coupled to the controller 300 of the three-dimensionally shaping apparatus 100 via the communication interface 440.

The CPU 410 functions as an acquisition section 411 and a data generating section 412 by executing a program stored in the storage 430.

The acquisition section 411 acquires designation information that designates the filling rate of the shaped object MD1.

The data generating section 412 generates shaping data that is data used to shape the three-dimensionally shaped object MD. The shaping data contains first shaping data, second shaping data, and third shaping data, which will be described later.

FIG. 7 shows steps of a method for manufacturing a three-dimensionally shaped object. The steps of steps S10 to S70 are executed in the information processing apparatus 400, and the steps of steps S80 and S90 are executed in the three-dimensionally shaping apparatus 100.

In step S10, the data generating section 412 of the information processing apparatus 400 acquires shape data representing the three-dimensional shape of the shaped object MD1 from another computer, a recording medium, or the storage 430. The shape data is data representing the shape of the three-dimensionally shaped object MD1 created by using three-dimensional CAD software, three-dimensional CG software, or the like. The shape data can, for example, be data in an STL format or an AMF format.

In step S20, the data generating section 412 generates slice data. The slice data refers to data representing the shape of the shaped object MD1 sliced into multiple layers. More specifically, the data generating section 412 generates the slice data by slicing the shape of the shaped object MD1 indicated by the shape data along the XY plane into multiple layers.

In step S30, the data generating section 412 accepts settings of shaping conditions relating to the three-dimensionally shaped object MD from a user. The user uses the input device 470 to operate a setting screen displayed on the display device 480 to set the shaping conditions. Examples of the shaping conditions include a linewidth, a shaping pattern, and a filling rate of a shaped object. The “linewidth” is the width of the plasticized material discharged from the nozzle 61. The “shaping pattern” is a pattern indicating the path along which the nozzle 61 is moved to fill the inner region ZD2 of each of the layers ML with the shaping or support material. The “filling rate of the shaped object” is an area proportion of the shaping material M3 that fills the inner region ZD2 in accordance with the designated shaping pattern. Assume now the user sets a value smaller than 100% as the filling rate of the shaped object. The shaping pattern is also hereinafter referred to as an infilling path pattern.

In step S40, the acquisition section 411 acquires the designation information. The acquisition section 411 acquires as the designation information the filling rate of the shaped object contained in the shaping conditions accepted by the data generating section 412 in step S30. Step S40 is also referred to as a first step.

In step S50, the data generating section 412 generates the first shaping data based on the slice data and the shaping conditions. The first shaping data is data instructing formation of the shaped object MD1 in the contour region ZD1. The first shaping data contains information on a first discharge quantity that is the quantity of the shaping material M3 discharged per unit time by the first discharger 60a, and information on a first discharge path that is the path along which the shaping material M3 is discharged. The path along which the shaping material M3 is discharged is the path along which the first nozzle 61a moves along and with respect to the shaping surface 211 of the stage 210. The first shaping data contains the information on the first discharge quantity and the information on the first discharge path for each of the multiple layers into which the shape of the shaped object MD1 has been sliced. The data generating section 412 preferably generates the first shaping data on a layer basis sequentially through the layers ML from top to bottom. Note that the data generating section 412 may generate the first shaping data on a layer basis sequentially through the layers ML from bottom to top.

FIG. 8 illustrates the path along which the plasticized material is discharged in one layer ML. FIG. 8 shows a state in which one layer ML is viewed from above. In step S50, the data generating section 412 determines the first discharge quantity and a first discharge path R1 used to form the shaped object MD1 in the contour region ZD1 shown in FIG. 8. FIG. 8 shows, as the first discharge path R1, a path that makes one round along the contour of the shaped object MD1. The first discharge path R1 may be a path that makes two or more rounds along the contour of the shaped object MD1. Step S50 is also referred to as a second step.

In step S60 in FIG. 7, the data generating section 412 generates the second shaping data based on the slice data and the shaping conditions. The second shaping data is data instructing formation of the shaped object MD1 in the inner region ZD2. The second shaping data contains information on a second discharge quantity that is the quantity of the shaping material M3 discharged per unit time by the first discharger 60a, and information on a second discharge path that is the path along which the shaping material M3 is discharged. The second shaping data contains the information on the second discharge quantity and the information on the second discharge path for each of the multiple layers into which the shape of the shaped object MD1 has been sliced. The data generating section 412 generates the second shaping data on a layer basis sequentially through the layers ML from top to bottom. Note that the data generating section 412 may generate the second shaping data on a layer basis sequentially through the layers ML from bottom to top.

In step S60, the data generating section 412 determines the second discharge quantity and a second discharge path R2 used to form the shaped object MD1 in the inner region ZD2 shown in FIG. 8. At this point of time, the data generating section 412 determines the second discharge quantity and the second discharge path R2 based on the designation information acquired in step S40. Specifically, the data generating section 412 determines the second discharge quantity and the second discharge path R2 in such a way that the filling rate of the shaping material M3 in each of the layers ML is equal to the designation information. The filling rate of the shaping material M3 in each of the layers ML is an area proportion of the shaping material M3 in the inner region ZD2 in the top view of the layer ML. The data generating section 412 generates the second shaping data in such a way that the second discharge path R2 in the inner region ZD2 and the first discharge path R1 in the contour region ZD1 are at least partially in contact with each other. Furthermore, the data generating section 412 generates the second shaping data in such a way that holes that communicate with the inner region ZD2 are formed in the three-dimensionally shaped object MD when the shaping of the three-dimensionally shaped object MD is completed. Specifically, the data generating section 412 generates the second shaping data in such a way that gaps formed inside the shaped object MD1 communicate with the outer space of the shaped object MD1. Step S60 is also referred to as a third step.

In step S70 in FIG. 7, the data generating section 412 generates the third shaping data based on the slice data and the shaping conditions. The third shaping data is data instructing formation of the support structure MD2 in the inner region ZD2. The third shaping data contains information on a third discharge quantity that is the quantity of the support material M4 discharged per unit time by the second discharger 60b, and information on a third discharge path that is the path along which the support material M4 is discharged. The path along which the support material M4 is discharged is the path along which the second nozzle 61b moves along and with respect to the shaping surface 211 of the stage 210. The third shaping data contains the information on the third discharge quantity and the information on the third discharge path for each of the multiple layers into which the shape of the shaped object MD1 has been sliced. The data generating section 412 generates the third shaping data on a layer basis sequentially through the layers ML from top to bottom. Step S70 includes step S71 and step S72. Step S70 is also referred to as a fourth step. Note that the data generation section 412 may generate the third shaping data on a layer basis sequentially through the layers ML from bottom to top.

In step S71, the data generating section 412 identifies gap regions ZD3, which are regions where the shaping material M3 is not discharged in the inner region ZD2. The data generating section 412 identifies portions of the inner region ZD2 where the second discharge path R2 is not located as the gap regions ZD3.

The data generating section 412 generates the third shaping data in step S72. The data generating section 412 generates the third shaping data in such a way that the support material M4 is discharged to the gap regions ZD3 identified in step S71, as shown in FIG. 8. That is, the data generating section 412 determines the third discharge quantity and a third discharge path R3 in such a way that the third discharge path R3 is at least partially located in each gap between segments of the second discharge path R2. The data generating section 412 preferably generates the third shaping data in such a way that the sum of the filling rate of the shaping material M3 and the filling rate of the support material M4 in each of the layers ML is a value close to 100%.

In step S80, the controller 300 of the three-dimensionally shaping apparatus 100 acquires, from the information processing apparatus 400, the shaping data including the first shaping data, the second shaping data, and the third shaping data generated by the information processing apparatus 400 in steps S50 to S70.

In step S90, the controller 300 controls the first discharger 60a, the second discharger 60b, and the moving mechanism 230 in accordance with the shaping data acquired from the information processing apparatus 400, and shapes the shaped object MD1 and the support structure MD2 on the shaping surface 211 of the stage 210 to shape the three-dimensionally shaped object MD. Step S90 is also referred to as a fifth step.

In step S100, the user separates the support structure MD2 from the shaped object MD1. The user dissolves the support structure MD2 by immersing the three-dimensionally shaped object MD in a liquid that dissolves only the support structure MD2 of the three-dimensionally shaped object MD, such as water and a solvent. Step S100 is also referred to as a sixth step.

According to the first f embodiment described above, the data generating section 412 generates the third shaping data in such a way that the third discharge path R3 is at least partially located in each gap between segments of the second discharge path R2 in one layer ML. Therefore, when the three-dimensionally shaped object MD is shaped, the support structure MD2 is formed in each gap present inside the shaped object MD1. The thus formed support structure MD2 can suppress shift of the positions of the shaping material M3 discharged to regions above the support structure MD2 due to gravity before the shaping material M3 cures. Even a low-filling-rate shaped object MD1 can therefore be shaped with high accuracy.

In the present embodiment, the data generating section 412 identifies the gap regions ZD3 and generates the third shaping data in such a way that the support material M4 is discharged to the gap regions ZD3. The present embodiment can therefore suppress discharging the support material M4 to the region where the shaping material M3 has already been discharged in the shaping of the three-dimensionally shaped object MD.

In the present embodiment, the data generating section 412 generates the second shaping data in such a way that the second discharge path R2 in the inner region ZD2 and the first discharge path R1 in the contour region ZD1 are at least partially in contact with each other. Therefore, when the support structure MD2 is separated from the shaped object MD1, separation of the shaped object MD1 in the contour region ZD1 from the shaped object MD1 in the inner region ZD2 can be suppressed.

In the present embodiment, the data generating section 412 generates the second shaping data in such a way that the holes that communicate with the inner region ZD2 are formed in the three-dimensionally shaped object MD. Accordingly, when the three-dimensionally shaped object MD is immersed in the liquid that dissolves only the support structure MD2, the liquid described above flows into the interior of the three-dimensionally shaped object MD. The support structure MD2 can therefore be readily separated from the shaped object MD1.

B. Second Embodiment

In a second embodiment, the process in step S72 of the method for manufacturing a three-dimensionally shaped object differs from that in the first embodiment. The processes other than that in step S72 and the configuration of the three-dimensionally shaping system 10 are the same as those in the first embodiment.

FIG. 9 illustrates the path along which the plasticized material is discharged in one layer ML in the second embodiment. FIG. 9 shows the state in which one layer ML is viewed from above. In the second embodiment, in step S72 in FIG. 7, the data generating section 412 generates the third shaping data in such a way that the support material M4 is discharged to some of the gap regions ZD3 identified in step S71. The data generating section 412 preferably determines the third discharge path R3 in such a way that the gap regions ZD3 are divided by the support material M4, as shown in FIG. 9. The data generating section 412 generates the third shaping data in such a way that the sum of the filling rate of the shaping material M3 and the filling rate of the support material M4 in each of the layers ML is a value smaller than 100%.

According to the second embodiment described above, the data generating section 412 generates the third shaping data in such a way that the third discharge path R3 is at least partially located in each gap between segments of the second discharge path R2 in one layer ML. Even a low-filling-rate shaped object MD1 can therefore be shaped with high accuracy, as in the first embodiment.

C. Third Embodiment

In a third embodiment, the process in step S72 of the method for manufacturing a three-dimensionally shaped object differs from that in the first embodiment. The processes other than that in step S72 and the configuration of the three-dimensionally shaping system 10 are the same as those in the first embodiment.

FIGS. 10 and 11 illustrate the path along which the plasticized material is discharged in one layer ML in the third embodiment. FIG. 10 shows a state in which the (n+1)-th layer is viewed from above. FIG. 11 shows a state in which the (n+2)-th layer is viewed from above.

The data generating section 412 generates the third shaping data on a layer basis sequentially through the layers ML from top to bottom. In the third embodiment, in step S72 in FIG. 7, the data generating section 412 generates the third shaping data on the (n+1)-th layer in such a way that the support material M4 is discharged to a region where the second discharge path R2 in the (n+2)-th layer and the gap regions ZD3 in the (n+1)-th layer overlap with each other in the vertical direction. In other words, the data generating section 412 determines the third discharge path R3 in the (n+1)-th layer in such a way that the support material M4 is discharged to a region where the region to which the shaping material M3 is discharged in the (n+2)-th layer and the gap regions ZD3 in the (n+1)-th layer overlap with each other in the vertical direction. When there is a region to which the support material M4 is discharged in the (n+2)-th layer, the data generating section 412 generates the third shaping data on the (n+1)-th layer in such a way that the support material M4 is discharged to a region where the second discharge path R2 or the third discharge path R3 in the (n+2)-th layer and the gap regions ZD3 in the (n+1)-th layer overlap with each other in the vertical direction.

FIG. 12 shows a part of the three-dimensionally shaped object MD shaped in accordance with the method for manufacturing a three-dimensionally shaped object according to the third embodiment. FIG. 12 is a cross-sectional side view of the three-dimensionally shaped object MD. The data generating section 412 generates the third shaping data as described above for all the layers ML. Accordingly, out of the gap regions ZD3 in the layers ML below the (n+2)-th layer, the third discharge path R3 is present in the regions that overlap with the second discharge path R2 in the (n+2)-th layer in the vertical direction. The third discharge path R3 in each of the layers ML is present in the regions that overlap with the second discharge path R2 or the third discharge path R3 in the layer ML immediately below the layer ML in question in the vertical direction. In other words, the data generating section 412 generates the third shaping data on the (n+1)-th layer in such a way that the support material M4 is discharged to the regions that overlap in the vertical direction with the second discharge path R2 or the third discharge path R3 in the n-th layer out of the regions where the second discharge path R2 in the (n+2)-th layer and the gap regions ZD3 in the (n+1)-th layer overlap with each other in the vertical direction.

According to the third embodiment described above, the data generating section 412 generates the third shaping data on the (n+1)-th layer in such a way that the support material M4 is discharged to the regions that overlap in the vertical direction with the second discharge path R2 or the third discharge path R3 in the n-th layer out of the regions where the second discharge path R2 in the (n+2)-th layer and the gap regions ZD3 in the (n+1)-th layer overlap with each other in the vertical direction. Therefore, in the shaping of the three-dimensionally shaped object MD, the support material M4 can be disposed at positions where the support material M4 supports the shaping material M3 in the layer ML immediately above. The thus disposed support material M4 can suppress shift of the positions of the shaping material M3 discharged to regions above the support structure MD2 due to gravity before the shaping material M3 cures, and even a low-filling-rate shaped object MD1 can be shaped with high accuracy.

In the present embodiment, the data generating section 412 generates the third shaping data for each of the layers sequentially through the layers ML from top to bottom. The third shaping data on the (n+1)-th layer can therefore be generated by using information on the third discharge path R3 in the (n+2)-th layer.

D. Fourth Embodiment

In a fourth embodiment, the processes in steps S60 and S70 of the method for manufacturing a three-dimensionally shaped object differ from those in the first embodiment. The processes other than those in steps S60 and S70 and the configuration of the three-dimensionally shaping system 10 are the same as those in the first embodiment.

FIG. 13 shows steps of the method for manufacturing a three-dimensionally shaped object according to the fourth embodiment. In FIG. 13, steps in which the same processes as those in FIG. 7 are carried out have the same reference characters as those in FIG. 7, and will not be described.

In step S61, the data generating section 412 generates the second shaping data by setting a part of the path of an infilling path pattern P1 indicating a movement path along which the discharger 60, which fills the inner region ZD2 with the shaping or support material, moves, as the second discharge path R2. FIG. 14 shows an example of the infilling path pattern P1. The infilling path pattern P1 is, when the nozzle 61 is moved along the infilling path pattern P1 to discharge the plasticized material, the movement path along which the discharged plasticized material fills the entire inner region ZD2.

FIG. 15 illustrates the path along which the plasticized material is discharged in one layer ML in the fourth embodiment. FIG. 15 shows the state in which one layer ML is viewed from above. The data generating section 412 determines a part of the infilling path pattern P1 shown in FIG. 14 as the second discharge path R2, as shown in FIG. 15. The data generating section 412 determines the second discharge path R2 in such a way that the filling rate of the shaping material M3 in each of the layers ML is equal to the designation information. The data generating section 412 determines the second discharge path R2 in such a way that the center of gravity of the shaped object MD1 after the support structure MD2 is separated is located in the vicinity of the center of the shaped object MD1.

In step S73 in FIG. 13, the data generating section 412 generates the third shaping data by setting the path other than the second discharge path R2 out of the infilling path pattern P1 as the third discharge path R3. The data generating section 412 determines the path other than the path determined as the second discharge path R2 in step S61 out of the infilling path pattern P1 shown in FIG. 14 as the third discharge path R3, as shown in FIG. 15.

According to the fourth embodiment described above, the data generating section 412 generates the second shaping data by setting a part of the path of the infilling path pattern P1 as the second discharge path R2, and generates the third shaping data by setting the path of the infilling path pattern P1 other than the second discharge path as the third discharge path R3. Therefore, in the shaping of the three-dimensionally shaped object MD, the support material M4 is discharged to the regions of the inner region ZD2 where the shaping material M3 is not discharged. The thus discharged support material M4 can suppress shift of the positions of the shaping material M3 discharged to regions above the support structure MD2 due to gravity before the shaping material M3 cures. Even a low-filling-rate shaped object MD1 can therefore be shaped with high accuracy.

E. Fifth Embodiment

In a fifth embodiment, the process in step S70 of the method for manufacturing a three-dimensionally shaped object differs from that in the first embodiment. The processes other than that in step S70 and the configuration of the three-dimensionally shaping system 10 are the same as those in the first embodiment.

In the fifth embodiment, in step S