Three-dimensional shaping apparatus and manufacturing method for three-dimensional shaped object

A three-dimensional shaping apparatus includes an ejecting section configured to eject a shaping material from a nozzle, a stage on which the shaping material is stacked, a driving section configured to change relative positions of the ejecting section and the stage, a cleaning mechanism including a brush and a blade, and a control section. The control section causes, in cleaning processing, the nozzle to reciprocate to traverse the cleaning mechanism a plurality of times to execute a cleaning operation for bringing at least one of the brush and the blade and the nozzle to come into contact. The control section causes, in the cleaning operation, the nozzle to reciprocate to come into contact with the brush or the blade in different positions of the brush or the blade. Temperature of the nozzle in the cleaning operation is lower than temperature of the nozzle at a stacking time of layers.

The present application is based on, and claims priority from JP Application Serial Number 2021-151413, filed Sep. 16, 2021, the disclosure of which is hereby incorporated by reference herein in its entirety.

BACKGROUND

1. Technical Field

The present disclosure relates to a three-dimensional shaping apparatus and a manufacturing method for a three-dimensional shaped object.

2. Related Art

JP-T-2010-530326 (Patent Literature 1) discloses a three-dimensional shaping apparatus including an end cleaning assembly including a flicker plate and a brush. The three-dimensional shaping apparatus brings an extrusion head into contact with the flicker plate and the brush to clean the extrusion head.

When the distal end of a head is caused to reciprocate with respect to a cleaning mechanism such as the flicker plate and the brush to perform cleaning, it is likely that a waste material adhering to the cleaning mechanism adheres to the head again and affects shaping accuracy.

SUMMARY

According to a first aspect of the present disclosure, a three-dimensional shaping apparatus is provided. The three-dimensional shaping apparatus includes: an ejecting section including a plasticizing mechanism for plasticizing a plasticizing material and generating a shaping material and a nozzle and configured to eject the shaping material from the nozzle; a stage on which the shaping material is stacked; a driving section configured to change relative positions of the ejecting section and the stage; a cleaning mechanism including a brush and a blade; and a control section configured to execute cleaning processing for cleaning the nozzle and control the ejecting section and the driving section to stack layers on the stage. The brush and the blade are disposed at height where the brush and the blade come into contact with the nozzle. The brush and the blade have a melting point higher than a plasticizing temperature of the plasticizing material and have hardness lower than hardness of the nozzle. The control section causes, in the cleaning processing, the nozzle to reciprocate to traverse the cleaning mechanism a plurality of times to execute a cleaning operation for bringing at least one of the brush and the blade and the nozzle to come into contact. The control section causes, in the cleaning operation, the nozzle to reciprocate to come into contact with the brush or the blade in different positions of the brush or the blade. Temperature of the nozzle in the cleaning operation is lower than temperature of the nozzle at a stacking time of the layers.

According to a second aspect of the present disclosure, there is provided a manufacturing method for a three-dimensional shaped object in a three-dimensional shaping apparatus including: an ejecting section including a plasticizing mechanism for plasticizing a plasticizing material and generating a shaping material and a nozzle and configured to eject the shaping material from the nozzle; a stage on which the shaping material is stacked; a driving section configured to change relative positions of the ejecting section and the stage; and a cleaning mechanism including a brush and a blade, the brush and the blade being disposed at height where the brush and the blade come into contact with the nozzle, the brush and the blade having a melting point higher than a plasticizing temperature of the plasticizing material and having hardness lower than hardness of the nozzle. The manufacturing method includes: a stacking step for controlling the ejecting section and the driving section to stack layers on the stage; and a cleaning step for causing the nozzle to reciprocate to traverse the cleaning mechanism a plurality of times to execute a cleaning operation for bringing at least one of the brush and the blade and the nozzle to come into contact. In the cleaning step, in the cleaning operation, the nozzle is caused to reciprocate to come into contact with the brush or the blade in different positions of the brush or the blade. Temperature of the nozzle in the cleaning operation is lower than temperature of the nozzle at a stacking time of the layers.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

A. First Embodiment

FIG.1is a diagram showing a schematic configuration of a three-dimensional shaping apparatus10in a first embodiment. InFIG.1, arrows along X, Y, and Z directions orthogonal to one another are shown. The X, Y, and Z directions are directions along an X axis, a Y axis, and a Z axis, which are three spatial axes orthogonal to one another. The X, Y, and Z directions respectively include both of directions on one side along the X axis, the Y axis, and the Z axis and opposite directions of the directions. The X axis and the Y axis are axes along the horizontal plane. The Z axis is an axis along the vertical line. A −Z direction is the vertical direction and a +Z direction is a direction opposite to the vertical direction. The −Z direction is referred to as “downward” as well and the +Z direction is referred to as “upward” as well. The X, Y, and Z directions inFIG.1and the X, Y, and z directions in the other figures represent the same directions.

The three-dimensional shaping apparatus10in this embodiment includes an ejecting section100, a material storing section20, a housing110, a driving section210, a stage220, a cleaning mechanism250, a control section300, and a display device400functioning as an informing section.

The ejecting section100includes a plasticizing mechanism30that plasticizes at least a part of a plasticizing material supplied from the material storing section20and generates a shaping material and a nozzle60. The ejecting section100ejects the shaping material plasticized by the plasticizing mechanism30from the nozzle60toward the stage220. The ejecting section100is called ejection head, discharging section, discharge head, extruding section, or extrusion head as well or is simply called head as well. In this specification, “ejection” includes meaning of “discharge” or “extrusion”.

The housing110includes a shaping space111on the inside. In the shaping space111, the stage220on which the shaping material is stacked is disposed. In the housing110, for example, an opening for causing the shaping space111and the outside to communicate and a door for opening and closing the opening may be provided. A user can take out a shaped object shaped on the stage220from the opening by opening the door to open the opening.

The driving section210changes relative positions of the ejecting section100and the stage220. In this embodiment, the driving section210includes a first driving section211that moves the stage220in the Z direction and a second driving section212that moves the ejecting section100in the X direction and the Y direction. The first driving section211is configured as a lifting and lowering device and includes a motor for moving the stage220in the Z direction. The second driving section212is configured as a horizontal conveying device and includes a motor for sliding the ejecting section100in the X direction and a motor for sliding the ejecting section100in the Y direction. The motors are driven under control by the control section300. In other embodiments, the driving section210may be configured to move the stage220or the ejecting section100in the three directions of X, Y, and Z or may be configured to move the stage220in the X direction and the Y direction and move the ejecting section100in the Z direction.

The cleaning mechanism250includes a brush251and a blade252for cleaning the nozzle60. The cleaning mechanism250is disposed in a region different from the stage220in the horizontal direction. The cleaning mechanism250is disposed, in the vertical direction, at height where the brush251and the blade252can come into contact with the nozzle60. In this embodiment, the cleaning mechanism250is connected to the housing110via a supporting section280. A purge waste material container260is provided below the cleaning mechanism250. A waste material removed by the cleaning mechanism250drops to and is collected in the purge waste material container260. The blade252is called flicker plate as well. The cleaning mechanism250is called chip wipe assembly as well.

The control section300is configured by a computer including one or more processors310, a storing section320including a main storage device and an auxiliary storage device, and an input and output interface that inputs and outputs signals from and to the outside. In this embodiment, the processor310executes a program stored in the storing section320, whereby the control section300is capable of controlling, based on shaping data for shaping a three-dimensional shaped object, the ejecting section100and the driving section210to execute three-dimensional shaping processing explained below and cleaning processing for cleaning a nozzle. The control section300may be configured not by the computer but by a combination of a plurality of circuits.

The display device400is connected to the control section300. The display device400is configured by, for example, a liquid crystal display or an organic EL display. In this embodiment, the display device400is provided in the housing110. However, the display device400may be disposed separately from the housing110.

FIG.2is a diagram showing a schematic configuration of the ejecting section100. The ejecting section100includes the plasticizing mechanism30, the nozzle60, and a flow-rate adjusting section70. The plasticizing mechanism30includes a material conveying mechanism40and a heating block90. A material stored in the material storing section20is supplied to the ejecting section100. Under the control by the control section300, the ejecting section100plasticizes, with the plasticizing mechanism30, at least a part of the material supplied from the material storing section20to generate a shaping material and ejects the generated shaping material from the nozzle60onto the stage220and stacks the shaping material on the stage220. The material stacked on the stage220is sometimes called stacked material. A method of three-dimensional shaping for ejecting the material from the nozzle60and stacking the ejected material to thereby shape a three-dimensional shaped object is sometimes called material extrusion (ME).

In this embodiment, “plasticization” is a concept including melting and means changing the material from a solid to a state having fluidity. Specifically, in the case of a material in which glass transfer occurs, the plasticization means setting the temperature of the material to a glass transfer point or higher. In the case of a material in which glass transfer does not occur, the plasticization means setting the temperature of the material to a melting point or higher.

A pellet or a material in a state of powder or the like is stored in the material storing section20in this embodiment. In this embodiment, the material stored in the material storing section20is pellet-like resin. The material storing section20in this embodiment is configured by a hopper. The material stored in the material storing section20is supplied to the material conveying mechanism40of the plasticizing mechanism30via a supply path22provided below the material storing section20to connect the material storing section20and the ejecting section100.

The heating block90includes a heater58. The heater58is controlled by the control section300and heated to a plasticizing temperature for plasticizing the material. The plasticizing temperature is different depending on a type of a material in use and is, for example, a glass transfer point or a melting point of the material. If the material is ABS resin, the plasticizing temperature is set to, for example, approximately 110° C., which is a glass transfer point of the ABS resin. A through-hole80is provided in the heating block90. The through-hole80is configured such that the nozzle60can be attached to and detached from the through-hole80. The material conveying mechanism40conveys the shaping material toward a nozzle channel61of the nozzle60attached to the through-hole80of the heating block90. The plasticizing mechanism30plasticizes the material supplied from the material storing section20to the material conveying mechanism40while conveying the material toward the nozzle channel61of the nozzle60with the material conveying mechanism40and heating the material with the heat of the heating block90.

The material conveying mechanism40in this embodiment includes a screw case31, a screw41housed in the screw case31, and a driving motor32that drives the screw41. The heating block90in this embodiment includes a case91including an opening94and a barrel50disposed in the case91. A communication hole56is provided in the barrel50. The opening94and the communication hole56communicate, whereby the through-hole80in this embodiment is formed. The heater58is incorporated in the barrel50. The screw41in this embodiment is a so-called flat screw and is sometimes called “scroll” as well.

The screw41has a substantially columnar shape, the height of which in a direction along a center axis RX thereof is smaller than the diameter thereof. The screw41includes, on a surface opposed to the barrel50, a groove forming surface42on which screw grooves45are formed. The groove forming surface42is opposed to a screw counter surface52of the barrel50explained below. The center axis RX in this embodiment coincides with a rotation axis of the screw41. Details of the configuration of the screw41are explained below.

The driving motor32is coupled to the surface on the opposite side of the groove forming surface42of the screw41. The driving motor32is driven under the control by the control section300. The screw41rotates centering on the center axis RX with torque generated by the rotation of the driving motor32. The driving motor32may be directly coupled to the screw41or may be coupled to the screw41via, for example, a speed reducer.

The barrel50includes a screw counter surface52opposed to the groove forming surface42of the screw41. The case91is disposed to cover the surface on the opposite side of the screw counter surface52of the barrel50, that is, the lower surface of the barrel50. The communication hole56and the opening94are provided in a position overlapping the center axis RX of the screw41. That is, the through-hole80is located in a position overlapping the center axis RX.

As explained above, the nozzle60is detachably attached to the through-hole80of the heating block90. The nozzle60is called nozzle chip as well. The nozzle channel61is provided in the nozzle60. The nozzle channel61includes a nozzle opening63at the distal end of the nozzle60and includes an inflow port65at the rear end of the nozzle60. The nozzle opening63is located in a position in the −Z direction of the inflow port65. The nozzle60in this embodiment ejects, from the nozzle opening63, toward the stage220, the material flowing into the nozzle channel61via the through-hole80and the inflow port65. A heater for heating the material in the nozzle channel61may be provided around the nozzle channel61.

The nozzle60includes a shield68above the distal end of the nozzle60. More specifically, the shield68is disposed between the nozzle opening63and the heating block90in the outer circumference of the nozzle60. The shield68has a disc shape in the horizontal direction. The shield68prevents the heat of the heating block90from being transferred to the stacked material.

The flow-rate adjusting section70rotates in the nozzle channel61to thereby change an opening degree of the nozzle channel61. In this embodiment, the flow-rate adjusting section70is configured by a butterfly valve. The flow-rate adjusting section70is driven by the valve driving section75under the control by the control section300. The valve driving section75is configured by, for example, a stepping motor. The control section300can adjust a flow rate of the shaping material flowing from the material conveying mechanism40to the nozzle60, that is, a flow rate of the shaping material ejected from the nozzle60by controlling a rotation angle of the butterfly valve using the valve driving section75. The flow-rage adjusting section70not only can adjust the flow rate of the shaping material but also can control ON/OFF of an outflow of the shaping material.

FIG.3is a schematic perspective view showing the configuration on the groove forming surface42side of the screw41. InFIG.3, the position of the center axis RX of the screw41is indicated by an alternate long and short dash line. As explained above, the screw grooves45are provided on the groove forming surface42. A screw center47, which is the center of the groove forming surface42of the screw41, is configured as a recess to which one ends of the screw grooves45are coupled. The screw center47is opposed to the communication hole56of the barrel50. The screw center47crosses the center axis RX.

The screw grooves45of the screw41configure so-called scroll grooves. The screw grooves45extend from the screw center47toward the outer circumference of the screw41to draw an arc. The screw grooves45may be configured to extend in an involute curve shape or a spiral shape. Convex ridges46configuring sidewalls of the screw grooves45and extending along the screw grooves45are provided on the groove forming surface42. The screw grooves45are continuous to material introducing ports44formed on a side surface43of the screw41. The material introducing ports44are portions that receive the material supplied via the supply path22of the material storing section20.

InFIG.3, an example of the screw41including three screw grooves45and three convex ridges46is shown. The number of the screw grooves45and the convex ridges46provided in the screw41is not limited to three. Only one screw groove45may be provided or two or more screw grooves45may be provided. InFIG.3, an example of the screw41in which the material introducing ports44are formed in three places is shown. The number of the material introducing ports44provided in the screw41is not limited to three. The material introducing port44may be provided only in one place or the material introducing ports44may be provided in two or more places.

FIG.4is a top view showing the configuration on the screw counter surface52side of the barrel50. As explained above, the communication hole56is formed in the center of the screw counter surface52. A plurality of guide grooves54are formed around the communication hole56on the screw counter surface52. Each of the guide grooves54is coupled to the communication hole56at one end and spirally extends from the communication hole56toward the outer circumference of the screw counter surface52. Each of the guide grooves54has a function of guiding the shaping material to the communication hole56. The one end of the guide groove54may not be coupled to the communication hole56. The guide grooves54may not be formed in the barrel50.

FIG.5is an explanatory diagram showing a schematic configuration of the cleaning mechanism250. As explained above, the cleaning mechanism250includes the brush251and the blade252. The brush251is configured by arranging a plurality of hair bundles in the Y direction. The blade252is a flat member extending in the Z direction and the Y direction. The distal end of the brush251and the distal end of the blade252face the +Z direction. The distal end of the blade252is disposed below the distal end of the brush251. As explained above, the brush251and the blade252are disposed at the height where the brush251and the blade252can come into contact with the nozzle60. The distal end of the brush251is disposed at height where the distal end of the brush251can come into contact with the shield68provided in the nozzle60. The distal end of the blade252is disposed at height where the distal end of the blade252does not come into contact with the shield68. In this embodiment, the brush251and the blade252are integrated by a fixture258and can be simultaneously replaced when being worn. The brush251and the blade252can be individually replaced.

The brush251and the blade252have a melting point higher than a plasticizing temperature of the plasticizing material plasticized in the ejecting section100. The brush251and the blade252have hardness lower than the hardness of the nozzle60. In this embodiment, the hardness means Vickers hardness. Further, in this embodiment, a modulus of elasticity of the blade252is higher than a modulus of elasticity of the brush251. In this embodiment, the modulus of elasticity means a Young's modulus. The nozzle60is formed by metal such as an ultrahard alloy, tool steel, or SUS. The brush251and the blade252are formed by metal such as SUS, iron, or brass. The brush251and the blade252may be respectively formed by resin. The brush251may be formed by a natural fiber or a chemical fiber. The blade252may be formed by ceramic. In the other embodiments, the moduli of elasticity of the blade252and the brush251may be the same. The modulus of elasticity of the brush251may be higher than the modulus of elasticity of the blade252.

The cleaning mechanism250further includes a purge section253. The purge section253is called purge ledge as well. In this embodiment, the purge section253, the blade252, and the brush251are arranged in a +X direction in this order. That is, the blade252is disposed between the purge section253and the brush251. The distal end in the +Z direction of the purge section253is lower than the distal end of the blade252. In cleaning processing explained below, a waste material ejected from the nozzle60drops and is collected in a spherical shape on the purge section253and drops to the purge waste material container260. The upper surface of the purge section253is configured as an inclined surface in order to accelerate the drop of the waste material. More specifically, the purge section253includes a first inclined surface254, a second inclined surface255, and a third inclined surface256in descending order of distances from the blade252and in ascending order of heights of positions in the vertical direction. The first inclined surface254, the second inclined surface255, and the third inclined surface256are respectively inclined such that the positions of the ends in the +X direction thereof are higher than the positions of the ends in a −X direction thereof. In this embodiment, inclination angles from the horizontal plane of the second inclined surface255and the third inclined surface256are larger than an inclination angle from the horizontal plane of the first inclined surface254.

FIG.6is a flow chart of three-dimensional shaping processing showing a manufacturing method for a three-dimensional shaped object. The three-dimensional shaping processing is executed when the control section300of the three-dimensional shaping apparatus10receives predetermined operation from the user.

In step S100, the control section300acquires shaping data from a computer, a recording medium, or the like on the outside. The shaping data includes, for each of layers forming the three-dimensional shaped object, shaping path data representing a moving path of the nozzle60. Ejection amount data representing an ejection amount of the material ejected from the nozzle60is correlated with the shaping path data.

Subsequently, in step S110, the control section300starts execution of stacking processing. The stacking processing is processing for controlling the driving section210and the ejecting section100according to the shaping data and causing the ejecting section100to eject the shaping material onto the stage220to thereby shape a three-dimensional shaped object including a plurality of layers. Step S110is referred to as stacking step as well.

During the execution of the stacking processing, in step S120, the control section300determines whether to execute cleaning processing. For example, the control section300determines to execute the cleaning processing, for example, when an ejection abnormality of the shaping material is detected in the plasticizing mechanism30, when a predetermined number of layers are formed, when a type of the shaping material is changed, or when a command for designating cleaning included in the shaping data is received. When determining to execute the cleaning processing, the control section300controls the flow-rate adjusting section70, temporarily stops the ejection of the shaping material from the nozzle60, and, in step S130, performs processing for selecting a cleaning operation for the nozzle60in the cleaning processing. Specifically, in step S130, the control section300selects one cleaning operation among a plurality of cleaning operations in which tracks for moving the nozzle60are different. In this embodiment, in the plurality of cleaning operations in which the tracks are different, contact start positions of the nozzle60and the cleaning mechanism250are respectively different.

FIG.7is an explanatory diagram of the cleaning operation in this embodiment. InFIG.7, a state in which the distal end of the nozzle60and the brush251and the blade252of the cleaning mechanism250are viewed from above is shown. A moving track of the nozzle60is indicated by a broken line. As shown inFIG.7, the cleaning mechanism250has a longitudinal direction. In this embodiment, the longitudinal direction in the Y direction. In this embodiment, in the cleaning operation, after bringing the distal end of the nozzle60into contact with the blade252, the control section300brings the distal end of the nozzle60into contact with the brush251. Thereafter, the control section300causes the nozzle60to reciprocate to traverse the brush251and the blade252a plurality of times. Specifically, in this embodiment, the control section300moves, from a contact start position where the nozzle60and the cleaning mechanism250come into contact first, the nozzle60in the longitudinal direction of the cleaning mechanism250following an M-shaped or W-shaped track, in other words, a track showing a triangular wave shape. Consequently, in the cleaning operation, the control section300can cause the nozzle60to reciprocate in the X direction such that the nozzle60comes into contact with the brush251or the blade252in a different position of the brush251or the blade252every time the nozzle60passes the brush251or the blade252. In this embodiment, the control section300starts the movement of the nozzle60in the contact start position and moves the nozzle60such that the nozzle60returns to the contact start position again. In this embodiment, in the cleaning operation, the control section300brings the nozzle60into contact with both of the brush251and the blade252. However, the control section300may bring the nozzle60into contact with one of the brush251and the blade252.

FIG.8is a diagram showing a relation between the contact start position and a shaping progress ratio. In this embodiment, in step S130explained above, the control section300determines the contact start position according to a present shaping progress ratio. The shaping progress ratio means a ratio of the number of layers stacked to the present to the number of all layers configuring the three-dimensional shaped object. For example, when the three-dimensional shaped object is configured by ten layers, the shaping progress ratio is 40% if the number of layers stacked to the present is four. In this way, in this embodiment, a plurality of cleaning operations having contact start positions corresponding to shaping progress ratios are prepared. The control section300selects a cleaning operation corresponding to the present shaping progress ratio out of the plurality of cleaning operations and executes the cleaning operation. The control section300moves the nozzle60from the determined contact start position to reciprocate once in the longitudinal direction of the cleaning mechanism250while following the track shown inFIG.7. For example, when the contact start position is not the end in the longitudinal direction of the cleaning mechanism250, the control section300moves the nozzle60from the contact start position in a +Y direction following the track shown inFIG.7, after the nozzle60reaches the end in the +Y direction, moves the nozzle60in a −Y direction, and, after the nozzle60reaches the end in the −Y direction, moves the nozzle60to the contact start position again. Besides, the control section300may move the nozzle60in a predetermined distance in the longitudinal direction of the cleaning mechanism250. In the other embodiments, the contact start position may be determined according to not the shaping progress ratio but a time from a shaping start, an amount of the material discharged to that point, the length of a path shaped to that point, or the like.

After selecting the cleaning operation in step S130inFIG.6, the control section300executes cleaning processing in step S140. Step S140is referred to as cleaning step as well.

FIG.9is a detailed flowchart of the cleaning processing. When the cleaning processing is executed, in step S300, the control section300controls the driving section210and moves the nozzle60onto the purge section253and, thereafter, controls the flow-rate adjusting section70and causes the nozzle60to eject a predetermined amount of the material toward the purge section253. The material ejected toward the purge section253is referred to as waste material as well. The waste material ejected to the purge section253drops to the purge waste material container260along the inclined surface on the purge section253. An amount of the ejected material is, for example, an amount equivalent to the volume of the nozzle channel61.

In step S310, the control section300controls the flow-rate adjusting section70and stops the ejection of the waste material from the nozzle60. When the ejection of the waste material is stopped, since a melted material does not flow to the nozzle60, the temperature of the nozzle60drops. When a heater is provided in the nozzle60, the control section300may stop the heater included in the nozzle60from step S310until the cleaning operation in step S320explained below ends. When a cooling section is included in the nozzle60, the control section300may cause the cooling section included in the nozzle60to operate from step S310until the cleaning operation in step S320explained below ends.

In step S320, the control section300executes the cleaning operation selected in step S130in a state in which the temperature of the nozzle60is lower than the temperature of the nozzle60at the stacking processing time.

Referring back toFIG.6, when the cleaning processing in step S140ends or when determining in step S120not to execute the cleaning processing, in step S150, the control section300determines whether the stacking processing is completed for all the layers, that is, the shaping of the three-dimensional shaped object is completed. If the stacking processing is not completed, the control section300returns the processing to step S110and subsequently continues the stacking processing. If the stacking processing is completed, in step S160, the control section300causes the storing section320to store an execution history of the cleaning processing.

FIG.10is a diagram showing an example of the execution history of the cleaning processing. In this embodiment, the control section300counts, for each position in the longitudinal direction of the cleaning mechanism250, the number of times the position is cleaned, that is, the number of times the nozzle60passes the position, and records a distribution of the number of times in the storing section320as the execution history of the cleaning processing. The execution history is reset when the cleaning mechanism250is replaced with a new cleaning mechanism250. The control section300may detect the replacement of the cleaning mechanism250with a sensor or the like or may detect the replacement of the cleaning mechanism250by receiving predetermined operation from the user.

In step S170inFIG.6, the control section300executes wear determination processing for determining a worn state of the cleaning mechanism250. In the wear determination processing, the control section300refers to the execution history of the cleaning processing stored in the storing section320and, when detecting that a cleaning position where the number of times of cleaning exceeds a predetermined number of times of cleaning is present in one or more places, determines that wear is present. When determining in step S180that wear is present, in step S190, the control section300controls next and subsequent cleaning operations not to cause the nozzle60to pass, in the next and subsequent cleaning operations, a worn place, that is, the cleaning position where it is determined that the wear is present. That is, the control section300excludes the worn place from target positions of the cleaning operation. In the other embodiments, for example, in the next and subsequent cleaning operations, when the nozzle60passes the worn place, the control section300may clean the nozzle60using a worn portion as well by further moving the nozzle60in the −Z direction in a place where the wear further worsens. When the wear worsens to a certain degree, the control section300may perform display for urging replacement of the cleaning mechanism250on the display device400. When determining in step S180that wear is absent, the control section300may skip the processing in step S190.

The three-dimensional shaping apparatus10in this embodiment explained above causes the nozzle60to reciprocate such that, in the cleaning operation, the nozzle60comes into contact with the brush251or the blade252in different positions of the brush251or the blade252and sets the temperature of the nozzle60in the cleaning operation lower than the temperature of the nozzle60at the layer stacking time. Accordingly, a waste material is prevented from collectively adhering to a specific place of the cleaning mechanism250. The waste material adhering to the cleaning mechanism250is prevented from being heated by contact with the nozzle60to be softened. As a result, it is possible to prevent the waste material adhering to the cleaning mechanism250from adhering to the nozzle60again. Consequently, it is possible to prevent the waste material adhering to the cleaning mechanism250from affecting shaping accuracy.

In this embodiment, in the cleaning processing, the selected cleaning operation among the plurality of cleaning operations in which the tracks for moving the nozzle60are different is executed. Therefore, it is possible to properly use the plurality of cleaning operations in which the tracks for moving the nozzle60are different and clean the nozzle60. In particular, in this embodiment, in the plurality of cleaning operations in which the tracks are different, contact start positions of the nozzle60and the cleaning mechanism250are respectively different. Therefore, it is possible to effectively prevent the waste material from adhering to a specific position of the cleaning mechanism250. Consequently, it is possible to effectively prevent the waste material adhering to the cleaning mechanism250from adhering to the nozzle60again.

In this embodiment, the contact start position in the cleaning operation is changed according to the shaping progress ratio. Therefore, every time the cleaning operation is executed, the cleaning operation different from the cleaning operation executed last time is executed. Accordingly, it is possible to effectively prevent the waste material from adhering to a specific position of the cleaning mechanism250. Consequently, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism250from adhering to the nozzle60again.

In this embodiment, the control section300causes the storing section320to store the execution history of the cleaning processing. Accordingly, the control section300can check a worn state of the cleaning mechanism250using the execution history. As a result, it is possible to cause the nozzle60to perform the cleaning operation to exclude a worn place of the cleaning mechanism250. It is possible to prevent the movement of the nozzle60to bring the nozzle60into contact with the worn place.

In this embodiment, the modulus of elasticity of the blade252included in the cleaning mechanism250is higher than the modulus of elasticity of the brush251. Accordingly, the material adhering to the nozzle60is easily removed by the blade252.

In this embodiment, the distal end of the blade252is disposed below the distal end of the brush251in the cleaning mechanism250. Therefore, the material adhering to the distal end of the nozzle60can be effectively removed by the blade252.

In this embodiment, the distal end of the brush251is disposed at the height where the distal end of the brush251can come into contact with the shield68and the distal end of the blade252is disposed at the height where the distal end of the blade252does not come into contact with the shield68. Therefore, the material adhering to the shield68can be removed by the brush251.

In this embodiment, in the cleaning operation, the control section300brings the distal end of the nozzle60into contact with the blade252and removes the shaping material adhering to the distal end of the nozzle60and, thereafter, brings the distal end of the nozzle60into contact with the brush251. Therefore, the nozzle60can be efficiently cleaned.

In this embodiment, in the cleaning processing, the control section300causes the nozzle60to eject the waste material on the purge section253and, thereafter, moves the nozzle60toward the brush251and the blade252. Therefore, it is possible to clean the nozzle60after removing the shaping material remaining in the nozzle channel61.

In this embodiment, during the shaping of the three-dimensional shaped object, the stacking processing and the cleaning processing are repeatedly executed. However, the cleaning processing may be executed not only during the shaping but also before the shaping of the three-dimensional shaped object is started or after the shaping of the three-dimensional shaped object is completed.

FIGS.11to14are explanatory diagrams of other examples of the cleaning operation. InFIG.11, an example is shown in which the nozzle60is moved in the longitudinal direction of the cleaning mechanism250following a track showing a rectangular wave shape. InFIG.12, an example is shown in which the nozzle60is moved in the longitudinal direction of the cleaning mechanism250following a track showing a sine wave shape. InFIG.13, an example is shown in which the nozzle60is moved in the longitudinal direction of the cleaning mechanism250following a track showing a sawtooth wave shape. As shown in these figures, in the cleaning operation, the control section300is capable of causing the nozzle60to reciprocate in various tracks. As shown inFIG.14, in the cleaning operation, the control section300may set the number of times the nozzle60traverses the brush251larger than the number of times the nozzle60traversers the blade252. Consequently, it is possible suppress wear of the blade252.

B. Second Embodiment

FIG.15is a flowchart of three-dimensional shaping processing in a second embodiment. The configuration of the three-dimensional shaping apparatus10in the second embodiment is the same as the configuration of the three-dimensional shaping apparatus10in the first embodiment.

As shown inFIG.15, in the three-dimensional shaping processing in the second embodiment, after acquiring shaping data in step S100, in step S105, the control section300selects a cleaning pattern. The cleaning pattern includes a plurality of cleaning operations in which tracks are different. In this embodiment, a plurality of types of the cleaning patterns are stored in the storing section320.

FIG.16is a diagram showing an example of the cleaning patterns. In this embodiment, a pattern A and a pattern B are stored in the storing section320as the cleaning patterns. In the pattern A, a track of a cleaning operation is specified such that a contact start position at the cleaning operation time moves from the −Y direction to the +Y direction as a shaping progress ratio increases. In the pattern B, a track of a cleaning operation is specified such that a contact start position at the cleaning operation time moves from the +Y direction to the −Y direction as the shaping progress ratio increases. In step S105explained above, the control section300alternately selects the pattern A and the pattern B every time the three-dimensional shaping processing is executed, that is, every time a three-dimensional shaped object is shaped.

In the three-dimensional shaping processing in the second embodiment, in step S130inFIG.15, the control section300selects a cleaning operation corresponding to a shaping progress ratio using the cleaning pattern selected in step S105and executes the cleaning operation in the cleaning processing in step S140. Processing in steps S110to S120and S150to S190has the same processing content as the processing content of the three-dimensional shaping processing in the first embodiment. Therefore, explanation of the processing is omitted.

According to the second embodiment explained above, a plurality of types of cleaning patterns including a plurality of cleaning operations in which tracks are different are stored in the storing section320. Every time a three-dimensional shaped object is shaped, the control section300executes the cleaning processing using a cleaning pattern selected out of the plurality of types of cleaning patterns. Accordingly, it is possible to effectively prevent a waste material from adhering to a specific position of the cleaning mechanism250. Consequently, it is possible to prevent the waste material adhering to the cleaning mechanism250from adhering to the nozzle60again. In this embodiment, the two types of cleaning patterns are described. However, three or more types of cleaning patterns may be stored in the storing section320.

FIG.17is a diagram showing a schematic configuration of a three-dimensional shaping apparatus11in a third embodiment. The three-dimensional shaping apparatus11in the third embodiment is different from the three-dimensional shaping apparatus10in the first embodiment in that the three-dimensional shaping apparatus11includes a waste-material removing section270. The other components are the same as the components of the three-dimensional shaping apparatus10in the first embodiment.

The waste-material removing section270removes a waste material adhering to the brush251or the blade252included in the cleaning mechanism250. The waste-material removing section270in this embodiment is configured by an air compressor that jets compressed air. The control section300drives the waste-material removing section270and removes the waste material adhering to the cleaning mechanism250at the start time or an end time of the three-dimensional shaping apparatus shown inFIG.6orFIG.15or before the execution or after the execution of the cleaning processing in step S140.

According to the third embodiment explained above, it is possible to remove the waste material adhering to the brush251and the blade252using the waste-material removing section270. Therefore, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism250from adhering to the nozzle60again.

The waste-material removing section270may remove both of the waste material adhering to the brush251and the waste material adhering to the blade252or may be directed to one of the brush251and the blade252to thereby remove the waste material adhering to the one of the brush251and the blade252.

The waste-material removing section270may be configured by not only the air compressor but also, for example, a brush capable of moving on the cleaning mechanism250. The waste-material removing section270may rub the brush against the cleaning mechanism250to thereby remove the waste material adhering to the brush251and the blade252.

FIG.18is a diagram showing a schematic configuration of a three-dimensional shaping apparatus12in a fourth embodiment. In the fourth embodiment, the three-dimensional shaping apparatus12includes two ejecting sections and two cleaning mechanisms. Specifically, the ejecting sections in this embodiment include a first ejecting section101including a first nozzle71that ejects a first shaping material and a second ejecting section102including a second nozzle72that ejects a second shaping material. The first shaping material and the second shaping material can be, for example, a combination of a material for shaping and a material for support. Besides, the first shaping material and the second shaping material can be, for example, a combination of materials having different colors and different qualities. The configuration of the first ejecting section101and the second ejecting section102is the same as the configuration of the ejecting section100in the first embodiment.

The cleaning mechanisms in this embodiment include a first cleaning mechanism261including a brush and a blade for cleaning the first nozzle71and a second cleaning mechanism262including a brush and a blade for cleaning the second nozzle72. The configuration of the first cleaning mechanism261and the second cleaning mechanism262is the same as the configuration of the cleaning mechanism250in the first embodiment. In this embodiment, it is assumed that the two cleaning mechanisms261and262are disposed at a predetermined interval in the X direction and purge sections, blades, and brushes included in the respective cleaning mechanisms261and262are arranged in the −Y direction in this order. In this embodiment, it is assumed that the longitudinal direction of the first cleaning mechanism261and the second cleaning mechanism262is the X direction.

In this embodiment, the control section300executes the three-dimensional shaping processing shown inFIG.6using the two ejecting sections101and102and the two cleaning mechanisms261and262. In the three-dimensional shaping processing in this embodiment, the two ejecting sections101and102are properly used and the stacking processing is executed. In the cleaning processing shown inFIG.9, the control section300causes the first nozzle71included in the first ejecting section101and the second nozzle72included in the second ejecting section102to respectively perform the cleaning operation shown inFIG.7to thereby simultaneously clean the first nozzle71and the second nozzle72using the first cleaning mechanism261and the second cleaning mechanism262.

According to the fourth embodiment explained above, the two nozzles71and72included in the two ejecting sections101and102can be simultaneously cleaned. Therefore, it is possible to reduce a time required for the cleaning processing. As a result, it is possible to efficiently execute the three-dimensional shaping processing. In this embodiment, an example is explained in which the two ejecting sections and the two cleaning mechanisms are included in the three-dimensional shaping apparatus12. However, three or more ejecting sections and three or more cleaning mechanisms may be included in the three-dimensional shaping apparatus12.

FIG.19is a diagram showing a schematic configuration of a three-dimensional shaping apparatus13in a fifth embodiment. The three-dimensional shaping apparatus13in the fifth embodiment is different from the three-dimensional shaping apparatus10in the first embodiment mainly in the configuration of an ejecting section. The other components and processing content of three-dimensional shaping processing are the same as the components and the processing content of the three-dimensional shaping processing of the three-dimensional shaping apparatus10in the first embodiment. Accordingly, in the following explanation, the configuration of the ejecting section is mainly explained.

The three-dimensional shaping apparatus13in this embodiment includes an ejecting section103, a material storing section23, the housing110, the driving section210, the stage220, and the control section300. The three-dimensional shaping apparatus13further includes a blower16. The blower16is configured as an air blower that performs air blasting toward the ejecting section103via a manifold17. In this embodiment, a part of the manifold17, the ejecting section103, the driving section210, and the stage220are housed in the shaping space111in the housing110.

The material storing section23in this embodiment is configured as a holder that stores a filament-like material. The material storing section23is configured to be capable of unwinding the material stored on the inside to the outside of the material storing section23.

FIG.20is a diagram showing a schematic configuration of the ejecting section103in this embodiment. The ejecting section103includes a heating block190including a heater and functioning as a plasticizing mechanism in which a through-hole180is provided, a nozzle73detachably attached to the through-hole180, and a material conveying mechanism140that conveys a material MF toward a nozzle channel74of the nozzle73attached to the heating block190. The ejecting section103further includes a shield92that is disposed between the material conveying mechanism140and the heating block190in the Z direction and suppresses heat transfer from the heating block190to the material conveying mechanism140. Unlike the material conveying mechanism40in the first embodiment, the material conveying mechanism140in this embodiment does not include the screw case31and the screw41and is configured by two wheels49. Unlike the heating block90in the first embodiment, the heating block190does not include the barrel50and the case91.

The nozzle73in this embodiment is inserted through the through-hole180and a shield opening93provided in the shield92from the −Z direction to thereby be attached to the heating block190. In this embodiment, the dimension in the Z direction of the nozzle73and the dimension in the Z direction of the nozzle channel74are longer than the dimension in the Z direction of the through-hole180. In this embodiment, an inflow port165provided at the rear end of the nozzle73is located in the +Z direction of the heating block190, more specifically, on the +Z direction side of the shield92.

The two wheels49configuring the material conveying mechanism140draw out, with the rotation thereof, the material MF in the material storing section23to the outside and guide the material MF to between the two wheels49and conveys the material MF toward the nozzle channel74of the nozzle73attached to the through-hole180of the heating block190. The heating block190plasticizes, with the heat of a not-shown heater incorporated in the heating block190, the material MF conveyed into the nozzle channel74of the nozzle73.

The material MF in this embodiment is cooled, near the inflow port165of the nozzle73, by air sent from the blower16via the manifold17. Consequently, plasticization of the material MF near the inflow port165is suppressed and the material MF is efficiently conveyed into the inflow port165. An outlet end18of the manifold17is located on the +Z direction side of the shield92. Consequently, the air delivered from the manifold17is easily guided to near the inflow port165by the shield92. Therefore, the material MF near the inflow port165is efficiently cooled.

The configuration of the cleaning mechanism250in this embodiment is the same as the configuration in the first embodiment. However, the distal end of the brush251does not come into contact with the shield92during the cleaning processing. This is because, in this embodiment, the shield92is located above the heating block190.

In the three-dimensional shaping apparatus13in this embodiment explained above as well, it is possible to clean the nozzle73using the cleaning mechanism250.

F. Other Embodiments

(F1) In the embodiments, the control section300selects the cleaning operation to be used out of the plurality of cleaning operations in which the contact start positions are different and executes the cleaning processing. In contrast, the control section300may select the cleaning operation to be used out of the plurality of cleaning operations in which the shapes of the tracks are different shown inFIGS.7and11to14.

(F2) In the embodiments, the control section300moves the nozzle60from the blade252side to the brush251side at the start time of the cleaning operation. In contrast, the control section300may move the nozzle60from the brush251side to the blade252side at the start time of the cleaning operation.

(F3) The control section300may respectively store, at the start time of the cleaning operation, the cleaning operation for moving the nozzle60from the blade252side to the brush251side and the cleaning operation for moving the nozzle60from the brush251side to the blade252side as cleaning operations in which tracks are different and select the cleaning operation to be used out of the cleaning operations. The control section300may respectively store a cleaning operation having a track from the +Y direction to the −Y direction and a cleaning operation having a track from the −Y direction to the +Y direction and select the cleaning operation to be used out of the cleaning operations.

(F4) In the embodiments, the control section300changes the contact start position in the cleaning operation according to the shaping progress ratio. In contrast, the control section300may select the contact start position at random using a random number. However, even when the control section300selects the contact start position at random, it is preferable to select the contact start position at random from a range excluding the contact start position in the last cleaning operation.

(F5) In the embodiments, the cleaning mechanism250includes the purge section253. In contrast, the cleaning mechanism250may not include the purge section253.

(F6) In the embodiments, the nozzles60and73include the shields68and92. In contrast, the nozzles60and73may not include the shields68and92.

(F7) In the embodiment, the recording of the execution history of the cleaning processing and the wear determination processing may not be executed. That is, the processing in steps S160to S190inFIGS.6and15may be omitted.

(F8) In the embodiments, the cleaning mechanism250is disposed in the region different from the stage220in the horizontal direction. In contrast, the cleaning mechanism250may be disposed, in the horizontal direction, in a region overlapping the stage220, the region being different from a shaping region of the stage220where the three-dimensional shaped object is shaped. Consequently, it is possible to provide a compact three-dimensional shaping apparatus.

G. Other Aspects

The present disclosure is not limited to the embodiments explained above and can be realized in various configurations without departing from the gist of the present disclosure. For example, technical features of the embodiments corresponding to technical features in aspects described below can be substituted and combined as appropriate in order to solve a part or all of the problems described above or in order to achieve a part or all of the effects described above. Unless the technical feature are explained as essential technical features in this specification, the technical features can be deleted as appropriate.

(1) According to a first aspect of the present disclosure, a three-dimensional shaping apparatus is provided. The three-dimensional shaping apparatus includes: an ejecting section including a plasticizing mechanism for plasticizing a plasticizing material and generating a shaping material and a nozzle and configured to eject the shaping material from the nozzle; a stage on which the shaping material is stacked; a driving section configured to change relative positions of the ejecting section and the stage; a cleaning mechanism including a brush and a blade; and a control section configured to execute cleaning processing for cleaning the nozzle and control the ejecting section and the driving section to stack layers on the stage. The brush and the blade are disposed at height where the brush and the blade come into contact with the nozzle. The brush and the blade have a melting point higher than a plasticizing temperature of the plasticizing material and have hardness lower than hardness of the nozzle. The control section causes, in the cleaning processing, the nozzle to reciprocate to traverse the cleaning mechanism a plurality of times to execute a cleaning operation for bringing at least one of the brush and the blade and the nozzle to come into contact. The control section causes, in the cleaning operation, the nozzle to reciprocate to come into contact with the brush or the blade in different positions of the brush or the blade. Temperature of the nozzle in the cleaning operation is lower than temperature of the nozzle at a stacking time of the layers.

With such an aspect, in the cleaning operation, the nozzle reciprocates to come into contact with different positions of the brush or the blade and the temperature of the nozzle in the cleaning operation is lower than the temperature of the nozzle at the stacking time of the layers. Therefore, it is possible to prevent the waste material adhering to the cleaning mechanism from adhering to the nozzle again. As a result, it is possible to prevent a waste material adhering to the cleaning mechanism from affecting shaping accuracy.

(2) In the aspect, the control section may execute a selected cleaning operation among a plurality of cleaning operations in which tracks for moving the nozzle are different. With such an aspect, it is possible to properly use the plurality of cleaning operations in which the tracks for moving the nozzle are different and clean the nozzle.

(3) In the aspect, contact start positions of the nozzle and the cleaning mechanism may be respectively different in the plurality of cleaning operations in which the tracks are different. With such an aspect, it is possible to effectively prevent the waste material from adhering to a specific position of the cleaning mechanism. Therefore, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism from adhering to the nozzle again.

(4) In the aspect, the control section may execute a cleaning operation different from a cleaning operation executed last time. With such an aspect, it is possible to prevent the waste material from adhering to a specific position of the cleaning mechanism. Therefore, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism from adhering to the nozzle again.

(5) In the aspect, the three-dimensional shaping apparatus may further include a storing section configured to store a plurality of types of cleaning patterns including the plurality of cleaning operations in which the tracks are different, and, every time a three-dimensional shaped object is shaped, the control section may execute the cleaning processing using a cleaning pattern selected out of the plurality of types of cleaning patterns. With such an aspect, it is possible to prevent the waste material from adhering to a specific position of the cleaning mechanism. Therefore, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism from adhering to the nozzle again.

(6) In the aspect, the control section may cause a storing section to store an execution history of the cleaning processing. With such an aspect, it is possible to check a worn state of the cleaning mechanism using the execution history.

(7) In the aspect, the three-dimensional shaping apparatus may further include a waste-material removing section configured to remove a waste material adhering to the brush or the blade. With such an aspect, it is possible to more effectively prevent the waste material adhering to the cleaning mechanism from adhering to the nozzle again.

(8) In the aspect, the nozzle may include a shield above a distal end of the nozzle, a distal end of the brush may be disposed at height where the distal end of the brush comes into contact with the shield, and a distal end of the blade may be disposed at height where the distal end of the blade does not come into contact with the shield. With such an aspect, it is possible to remove a material adhering to the shield.

(9) In the aspect, the cleaning mechanism may include a purge section, the blade may be disposed between the purge section and the brush, the purge section may include a first inclined surface, a second inclined surface, and a third inclined surface in descending order of distances from the blade and in ascending order of heights of positions in the vertical direction, and inclination angles from a horizontal plane of the second inclined surface and the third inclined surface may be larger than an inclination angle from the horizontal plane of the first inclined surface.

(10) In the aspect, in the cleaning processing, the control section may move the nozzle toward the brush and the blade after causing the nozzle to eject the shaping material on the purge section. With such an aspect, it is possible to clean the nozzle after removing a material remaining in the nozzle.

(11) According to a second aspect of the present disclosure, there is provided a manufacturing method for a three-dimensional shaped object in a three-dimensional shaping apparatus including: an ejecting section including a plasticizing mechanism for plasticizing a plasticizing material and generating a shaping material and a nozzle and configured to eject the shaping material from the nozzle; a stage on which the shaping material is stacked; a driving section configured to change relative positions of the ejecting section and the stage; and a cleaning mechanism including a brush and a blade, the brush and the blade being disposed at height where the brush and the blade come into contact with the nozzle, the brush and the blade having a melting point higher than a plasticizing temperature of the plasticizing material and having hardness lower than hardness of the nozzle. The manufacturing method includes: a stacking step for controlling the ejecting section and the driving section to stack layers on the stage; and a cleaning step for causing the nozzle to reciprocate to traverse the cleaning mechanism a plurality of times to execute a cleaning operation for bringing at least one of the brush and the blade and the nozzle to come into contact. In the cleaning step, in the cleaning operation, the nozzle is caused to reciprocate to come into contact with the brush or the blade in different positions of the brush or the blade. Temperature of the nozzle in the cleaning operation is lower than temperature of the nozzle at a stacking time of the layers.