Patent Publication Number: US-2022227043-A1

Title: Shaping method and shaping device

Description:
TECHNICAL FIELD 
     The present disclosure relates to a shaping method and a shaping device for performing shaping by using a curable viscous fluid and a fluid containing metal particles. 
     BACKGROUND ART 
     In the conventional art, a technique for forming a structure with a curable viscous fluid such as an ultraviolet curable resin has been developed. Specifically, a curable viscous fluid is ejected by an ejection device, and is cured by irradiating the curable viscous fluid with ultraviolet light or the like. Consequently, a cured layer of the curable viscous fluid is formed. Patent Literature 1 discloses a technique in which a curable viscous fluid is ejected and then a surface of the ejected curable viscous fluid is planarized by a planarization device such as a roller. 
     Patent Literature 
     Patent Literature 1: JP-A-2013-67118 
     SUMMARY OF THE INVENTION 
     Technical Problem 
     Fine unevenness may be formed on a surface of a curable viscous fluid planarized by a planarization device. For example, unevenness caused by a size of liquid droplets of the curable viscous fluid is formed on the surface. A height difference between the unevenness caused by the size of the liquid droplets of the curable viscous fluid may be, for example, ± 10  pm (micrometer), and is extremely small compared with a size of a roller or the like. Thus, in a planarization device such as a roller, sufficient planarization cannot be performed, and thus there is concern that fine unevenness may be left on the surface of the curable viscous fluid after a planarization process is executed. 
     Here, in a case where a metallic conductor is shaped by ejecting and curing a fluid containing metal particles on a surface of a cured layer in which a planarized curable viscous fluid is cured, a thickness of the shaped conductor is made nonuniform due to unevenness of the surface. As a result, there is concern that a portion having a thickness may not be sufficiently metallized to the inside during baking, a resistance value may be made nonuniform due to a variation in the thickness of the conductor, or the high-frequency characteristic of the conductor may deteriorate. 
     The present disclosure has been made in view of such circumstances, and an object thereof is to provide a shaping method and a shaping device capable of achieving both planarization of a cured layer shaped from a curable viscous fluid and improvement of characteristics of a conductor shaped from a fluid containing metal particles. 
     Solution to Problem 
     In order to achieve the object, according to the present disclosure, there is provided a shaping method including a first ejection step of ejecting a first curable viscous fluid; a planarization step of planarizing, by a planarization device, the first curable viscous fluid ejected in the first ejection step; a first curing step of curing the first curable viscous fluid planarized in the planarization step; a cured layer forming step of repeatedly executing the first ejection step, the planarization step, and the first curing step to form a cured layer; a second ejection step of ejecting a second curable viscous fluid onto a surface of the cured layer; a second curing step of forming a smooth surface on the surface of the cured layer by curing the second curable viscous fluid ejected in the second ejection step without planarizing the second curable viscous fluid by the planarization device; a third ejection step of ejecting a fluid containing metal particles onto the smooth surface; and a third curing step of curing the fluid containing the metal particles ejected in the third ejection step to form a metallic conductor on the smooth surface. 
     In order to achieve the object, according to the present disclosure, there is provided a shaping device including an ejection device; a planarization device; a curing device; and a control device, in which the control device includes a first ejection section configured to cause the ejection device to eject a first curable viscous fluid, a planarization section configured to cause the planarization device to planarize the first curable viscous fluid ejected by the first ejection section, a first curing section configured to cause the curing device to cure the first curable viscous fluid planarized by the planarization section, a cured layer forming section configured to repeatedly execute processes performed by the first ejection section, the planarization section, and the first curing section to form a cured layer, a second ejection section configured to cause the ejection device to eject a second curable viscous fluid onto a surface of the cured layer, a second curing section configured to cause the curing device to cure the second curable viscous fluid ejected by the second ejection device to form a smooth surface on the surface of the cured layer without planarizing the second curable viscous fluid by the planarization device, a third ejection section configured to cause the ejection section to eject a fluid containing metal particles onto the smooth surface, and a third curing section configured to cause the curing device to cure the fluid containing the metal particles ejected by the third ejection section to form a metallic conductor on the smooth surface. 
     Advantageous Effect of the Invention 
     According to such a configuration, the first ejection step, the planarization step, and the first curing step are repeatedly executed to form a cured layer having a planarized surface. Fine unevenness that cannot be eliminated by the planarization device may be formed on the planarized surface of the cured layer. 
     Therefore, the second curable viscous fluid is ejected onto the surface of the cured layer, and the ejected second curable viscous fluid is cured without being planarized by the planarization device. Consequently, the second curable viscous fluid ejected on the surface of the cured layer is spread over the fine unevenness of the surface of the cured layer due to the leveling effect, and is smoothed to form, for example, a smooth surface having surface unevenness of ±1 μm or less. By ejecting a fluid containing metal particles onto the smooth surface and curing the fluid, a conductor having a more uniform thickness (having higher electrical characteristics) can be formed on the cured layer. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a diagram illustrating a shaping device of the present embodiment. 
         FIG. 2  is a block diagram illustrating a control device. 
         FIG. 3  is a flowchart illustrating details of a shaping process. 
         FIG. 4  is a schematic diagram illustrating a state in which an ultraviolet curable resin is being ejected from an ink jet head. 
         FIG. 5  is a schematic diagram illustrating a state in which an ultraviolet curable resin is being planarized by a planarization device. 
         FIG. 6  is a schematic diagram illustrating a state in which a planarized ultraviolet curable resin is being cured by a curing section to form an insulating layer. 
         FIG. 7  is a schematic diagram illustrating an insulating layer of which a surface has been planarized. 
         FIG. 8  is a schematic diagram illustrating a state in which a second ultraviolet curable resin is being ejected onto the surface of the insulating layer. 
         FIG. 9  is a schematic diagram illustrating a state in which the second ultraviolet curable resin is being heated. 
         FIG. 10  is a schematic diagram illustrating an insulating layer of which a surface has been smoothed. 
         FIG. 11  is a schematic diagram illustrating a state in which metal ink is being ejected on a smooth surface. 
         FIG. 12  is a schematic diagram illustrating a state in which a metal wiring is being formed. 
     
    
    
     DESCRIPTION OF EMBODIMENTS 
     (1. Configuration of Shaping Device  10 ) 
       FIG. 1  illustrates shaping device  10  of one embodiment embodying a shaping device of the present disclosure. Shaping device  10  of the present embodiment includes conveyance device  20 , shaping unit  22 , mounting unit  23 , inspection unit  24 , and control device  26  (refer to  FIG. 2 ). Conveyance device  20 , shaping unit  22 , mounting unit  23 , and inspection unit  24  are disposed on base  28  of shaping device  10 . Base  28  generally has a rectangular shape. In the following description, a longitudinal direction of base  28  will be referred to as an X-axis direction, a lateral direction of base  28  will be referred to as a Y-axis direction, and a direction orthogonal to both of the X-axis direction and the Y-axis direction will be referred to as a Z-axis direction. 
     Conveyance device  20  includes X-axis slide mechanism  30  and Y-axis slide mechanism  32 . X-axis slide mechanism  30  includes X-axis slide rail  34  and X-axis slider  36 . X-axis slide rail  34  is disposed to extend in the X-axis direction on base  28 . X-axis slider  36  is held by X-axis slide rail  34  to be slidable in the X-axis direction. X-axis slide mechanism  30  further includes electromagnetic motor  38  (refer to  FIG. 2 ), and moves X-axis slider  36  to any position in the X-axis direction by driving electromagnetic motor  38 . 
     Y-axis slide mechanism  32  includes Y-axis slide rail  50  and stage  52 . Y-axis slide rail  50  is disposed to extend in the Y-axis direction on base  28 . One end part of Y-axis slide rail  50  in the Y-axis direction is coupled to X-axis slider  36 . Consequently, Y-axis slide rail  50  is configured to be movable in the X-axis direction in accordance with sliding movement of X-axis slider  36 . Stage  52  is held to be slidable in the Y-axis direction by Y-axis slide rail  50 . Y-axis slide mechanism  32  has electromagnetic motor  56  (refer to  FIG. 2 ), and moves stage  52  to any position in the Y-axis direction by driving electromagnetic motor  56 . Consequently, stage  52  can be moved to any position in the X-axis direction and the Y-axis direction on base  28  by driving X-axis slide mechanism  30  and Y-axis slide mechanism  32 . 
     Stage  52  has base plate  60 , holding devices  62 , and lifting/lowering device  64 . Base plate  60  is formed in a flat plate shape, and base member  70  (refer to  FIG. 4 ) is placed on an upper surface thereof. Base member  70  is, for example, a plate made of a metal such as iron or stainless steel. Holding devices  62  are provided on both sides of base plate  60  in the X-axis direction. Both edges in the X-axis direction of base member  70  placed on base plate  60  are sandwiched by holding device  62 , and thus base member  70  is fixedly held to base plate  60 . Lifting/lowering device  64  is disposed below base plate  60  to move up and down base plate  60  in the Z-axis direction. 
     Shaping unit  22  is a unit that shapes a structure on base member  70  placed on base plate  60  of stage  52 , and includes printing section  72  and curing section  74 . As illustrated in  FIG. 4 , printing section  72  has ink jet head  75 , and ejects a fluid in a thin film form on base member  70  placed on base plate  60 . As the fluid ejected by ink jet head  75 , ultraviolet curable resin  76  (refer to  FIG. 4 ) that is cured by ultraviolet light may be employed. Ultraviolet curable resin  76  is an example of first and second curable viscous fluids of present application. As the curable viscous fluid, other viscous fluids such as a thermosetting resin may be employed in addition to an ultraviolet curable resin. 
     In addition to ultraviolet curable resin  76 , ink jet head  75  is configured to be capable of ejecting, for example, metal ink  77  (refer to  FIG. 11 ). Metal ink  77  is an example of a fluid containing metal particles of present application. Metal ink  77  is, for example, one in which fine particles of a metal (silver or the like) having a nanometer size are dispersed in a solvent, and is baked and cured by heat. A surface of the metal fine particle is coated with, for example, a dispersant to suppress aggregation in the solvent. 
     In a case of ejecting ultraviolet curable resin  76 , ink jet head  75  ejects ultraviolet curable resin  76  from multiple nozzles according to, for example, a piezo method using piezoelectric elements, or ejects ultraviolet curable resin  76  from multiple nozzles according to a thermal method in which air bubbles are generated by heating ultraviolet curable resin  76  and ejected from nozzles. In a case of ejecting metal ink  77 , ink jet head  75  ejects metal ink  77  from multiple nozzles, for example, according to a piezo method using piezoelectric elements. An ejection device is not limited to ink jet head  75  including multiple nozzles, and may be, for example, a dispenser including a single nozzle. Ink jet head  75  may separately include a nozzle ejecting metal ink  77  and a nozzle ejecting ultraviolet curable resin  76 , or may share a nozzle ejecting two viscous fluids. In the following description, ultraviolet curable resin  76  and metal ink  77  may be collectively referred to as a viscous fluid. 
     As illustrated in  FIG. 2 , curing section  74  includes planarization device  78 , irradiation device  81 , and heater  82 . Planarization device  78  is a device planarizing an upper surface of ultraviolet curable resin  76  or metal ink  77  ejected on base member  70  by ink jet head  75 . Planarization device  78  includes roller  79  and collection section  80  (refer to  FIG. 5 ). Roller  79  has, for example, a cylindrical shape, and, based on control of planarization device  78 , moves while rotating on a surface of a viscous fluid (ultraviolet curable resin  76  or metal ink  77 ) in a flowable state to planarize the surface. Collection section  80  has, for example, a blade protruding toward a surface of roller  79 , and stores and discharges the viscous fluid scraped by the blade. Collection section  80  discharges, for example, the collected viscous fluid to a waste liquid tank. Planarization device  78  planarizes the surface of the viscous fluid by scraping the excess viscous fluid while leveling the surface of the viscous fluid. 
     Planarization device  78  is not limited to a configuration in which planarization is performed by roller  79 . For example, planarization device  78  may have a configuration in which a plate-shaped member such as a squeegee comes into contact with the surface of the viscous fluid to perform planarization. Alternatively, planarization device  78  may have a configuration for leveling the surface of the viscous fluid by using a brush or a rake. Collection section  80  may return the collected viscous fluid to a supply tank again. The planarization by planarization device  78  may not be performed every time the viscous fluid is ejected. For example, the planarization may be performed only when a specific layer is formed. 
     Irradiation device  81  irradiates, for example, ultraviolet curable resin  76  ejected on base member  70  with ultraviolet light. Ultraviolet curable resin  76  is cured due to irradiation with the ultraviolet light to form insulating layer  86  in the thin film form (refer to  FIGS. 6 and 7 ). Heater  82  is a device heating the ejected ultraviolet curable resin  76  or metal ink  77 . Ultraviolet curable resin  76  of the present embodiment has a property in which viscosity is reduced by being heated. In a heating process (refer to S 21  in  FIG. 3 ) that will be described later, shaping device  10  heats ultraviolet curable resin  76  to reduce the viscosity, and thus more effectively performs smoothing. 
     Metal ink  77  is baked by heat being applied from heater  82  to form a metal wiring. Baking of metal ink  77  is, for example, a phenomenon in which evaporation of a solvent or decomposition of a protective film of metal fine particles, that is, a dispersant is performed by applying energy, so that conductivity is increased by contacting or fusing the metal fine particles. A metal wiring may be formed by baking the metal ink. Details of a shaping method will be described later. A device that heats metal ink  77  is not limited to heater  82 . For example, shaping device  10  may include a laser irradiation device that irradiates metal ink  77  with laser light as a device that heats metal ink  77 , or an atmosphere furnace that heats insulating layer  86  on which metal ink  77  is ejected inside the furnace. 
     Mounting unit  23  illustrated in  FIG. 1  is, for example, a unit that mounts various electronic components connected to the metal wiring shaped by shaping unit  22 , and includes mounting section  83  and supply section  84 . Mounting section  83  has, for example, a suction nozzle (not illustrated) that picks up an electronic component, and mounts the electronic component held by the suction nozzle. Supply section  84  has, for example, multiple tape feeders that feed taped electronic components one by one, and supplies the electronic components to mounting section  83 . Supply section  84  is not limited to the configuration including the tape feeder, and may be a tray-type supply device that picks up an electronic component from a tray and supplies the electronic component. 
     For example, when base member  70  is moved to a position below mounting section  83  in accordance with movement of stage  52 , mounting unit  23  moves mounting section  83  to a component supply position of supply section  84 , and drives supply section  84  to supply a necessary component. Mounting section  83  picks up and holds the electronic component from the component supply position of supply section  84  by using the suction nozzle, and mounts the electronic component on insulating layer  86  shaped on base member  70 . 
     Inspection unit  24  is a unit that inspects a structure shaped by shaping unit  22  and mounting unit  23 . Inspection unit  24  includes, for example, an imaging device such as a camera. Control device  26  may determine whether an electronic component is normally mounted based on image data captured by inspection unit  24 . 
     Inspection unit  24  of the present embodiment includes a device for inspecting smooth surface  93  (refer to  FIG. 10 ) that will be described later. For example, inspection unit  24  includes a confocal laser microscope capable of measuring a surface roughness of smooth surface  93 . Based on a result measured by the confocal laser microscope of inspection unit  24 , control device  26  can determine whether the unevenness of smooth surface  93  is favorable, that is, whether smoothing is executed to a desired state. Details of the inspection will be described later. Shaping device  10  does not have to include a device (such as inspection unit  24 ) inspecting smooth surface  93 . 
     As illustrated in  FIG. 2 , control device  26  includes controller  102 , multiple driving circuits  104 , and storage device  106 . Multiple driving circuits  104  are connected to electromagnetic motors  38  and  56 , holding device  62 , lifting/lowering device  64 , ink jet head  75 , planarization device  78 , irradiation device  81 , heater  82 , mounting section  83 , supply section  84 , and inspection unit  24 . Controller  102  includes a CPU, a ROM, a RAM, and the like, and is mainly a computer, and is connected to multiple driving circuits  104 . Storage device  106  includes a RAM, a ROM, a hard disk, and the like, and stores control program  107  for performing control of shaping device  10 . Controller  102  may control operations of conveyance device  20 , shaping unit  22 , and the like by executing control program  107  with the CPU. 
     According to the configuration described above, shaping device  10  of the present embodiment forms insulating layer  86  (refer to  FIG. 7 ) or metal wiring  95  (refer to  FIG. 12 ) by curing ultraviolet curable resin  76  or metal ink  77  as a viscous fluid. Shaping device  10  can shape a structure having any shape by changing a shape of insulating layer  86  or metal wiring  95 . In shaping device  10 , an electronic component is mounted by mounting unit  23  in the process of shaping. For example, three-dimensional data of each layer obtained by slicing a structure is set in control program  107 . Controller  102  forms a structure by ejecting, curing, or the like a viscous fluid based on data of control program  107 . Controller  102  detects information such as a layer or a position where an electronic component is disposed based on the data of control program  107 , and mounts the electronic component based on the detected information. 
     (2. Operation of Shaping Device  10 ) 
     In the following description, as an example of an operation of shaping device  10 , a shaping process of shaping a metal wiring on an insulating layer will be described.  FIG. 2  is a flowchart illustrating details of the shaping process. For example, when an instruction for starting shaping is received, control device  26  executes a predetermined program in control program  107 , and starts the shaping process illustrated in  FIG. 2 . In the following description, the expression that controller  102  executes control program  107  to control each device may be simply referred to as a “device”. For example, the expression that “controller  102  moves base plate  60 ” means that “controller  102  executes control program  107 , controls an operation of conveyance device  20  via driving circuit  104 , and moves base plate  60  through an operation of conveyance device  20 ”. 
     First, base member  70  is set on base plate  60  of stage  52 . The setting of base member  70  may be performed by a human, or may be automatically executed by shaping device  10 . Controller  102  controls conveyance device  20  to move stage  52  on which base member  70  is set to a position below shaping unit  22 . In a first ejection process shown in S 11  in  FIG. 3 , controller  102  controls ink jet head  75  of printing section  72  to eject ultraviolet curable resin  76  onto base member  70  (refer to  FIG. 4 ).  FIG. 4  is a schematic diagram illustrating a state in which ultraviolet curable resin  76  is being ejected from ink jet head  75 . Ink jet head  75  ejects ultraviolet curable resin  76  in a thin film form onto base member  70 . Controller  102  may execute ejection using ink jet head  75  in S 11 , for example, by only one scan (one pass) along the X-axis direction, or may execute ejection by multiple scans.
         Next, in a planarization process in S 13 , controller  102  rotates roller  79  of planarization device  78  on the upper surface of ultraviolet curable resin  76  in the thin film form to perform planarization. As indicated by an arrow in  FIG. 5 , controller  102  moves roller  79  in a direction opposite to a direction in which base member  70  is moved, and the planarization process is executed in synchronization with operations of base member  70  and roller  79 . Roller  79  scrapes up ultraviolet curable resin  76  in a flowable state, collects the ultraviolet curable resin  76  with collection section  80 , and planarizes the surface of ultraviolet curable resin  76 . Operation directions and the like of base member  70  and roller  79  described above are examples. For example, controller  102  may move roller  79  in the same direction as that of base member  70 , or may move only roller  79  while fixing a position of base member  70 . Controller  102  may advance roller  79  while rotating roller  79  in the front direction or may advance roller  79  while rotating roller  79  in the rear direction. Alternatively, controller  102  may not rotate roller  79 .       

     Next, in first curing process in S 15 , controller  102  irradiates planarized ultraviolet curable resin  76  with ultraviolet light by irradiation device  81 . As illustrated in  FIG. 6 , irradiation device  81  cures ultraviolet curable resin  76  by irradiating ultraviolet light to ultraviolet curable resin  76  (refer to  FIG. 5 ) spread in a thin film form to form insulating layer  86  having insulating property. Consequently, insulating layer  86  in which surface  86 A is planarized can be formed. 
     Next, controller  102  determines whether desired insulating layer  86  having planarized surface  86 A has been formed (S 17 ). Controller  102  performs a negative determination in S 17 , for example, until a thickness, a shape, or the like designated by control program  107  or an operation input from the outside is reached (S 17 : NO). Controller  102  may determine the thickness, the shape, or the like of formed insulating layer  86 , for example, based on a size of liquid droplets of ultraviolet curable resin  76  ejected from ink jet head  75 , the number of times in which S 11  to S 15  are executed, and the like. Controller  102  repeatedly executes the processes in S 11  to S 15  to laminate insulating layer  86 , and thus surface  86 A is planarized and insulating layer  86  having a desired shape (a thickness, a shape, or the like) is formed. Controller  102  does not have to execute the planarization process in S 13  each time S 11  is executed. For example, controller  102  may execute the planarization process in S 13  each time S 11  and S 15  are executed multiple times. 
     When it is determined in S 17  that surface  86 A is planarized and insulating layer  86  having a desired shape is formed (S 17 : YES), controller  102  ejects ultraviolet curable resin  76  again onto surface  86 A in order to smooth surface  86 A of planarized insulating layer  86  in a second ejection process in S 19 . 
     Here, S 11  to S 15  are repeatedly executed, and thus insulating layer  86  having planarized surface  86 A can be formed.  FIG. 7  schematically illustrates an insulating layer  86  of which a surface is planarized. As illustrated in  FIG. 7 , fine unevenness  91  is formed on surface  86 A of planarized insulating layer  86  due to, for example, a difference in an amount of ultraviolet curable resin  76  ejected from the nozzles of ink jet head  75 , a size of liquid droplets of ultraviolet curable resin  76 , or the like. A height of unevenness  91  may be, for example, ±10 μm, and is extremely small compared with a size of roller  79 . Therefore, even if surface  86 A of insulating layer  86  is planarized by roller  79 , it is difficult to planarize surface  86 A to fine unevenness  91 . In the present application, the surface on which fine unevenness  91  is formed is defined as a planarized surface. A surface on which fine unevenness  91  is reduced, or the unevenness of the surface is equal to or less than ±1 μm (it can be assumed that original unevenness  91  is eliminated) is defined as a smooth surface that is smoothed. 
     When unevenness  91  is formed on surface  86 A, in a case where a metal wiring is formed on surface  86 A, a thickness of the metal wiring to be formed varies. Alternatively, there is concern that the conductivity of the metal wiring may be reduced by not completely baking the metal wiring in a portion having a large thickness (metal fine particles do not contact or fuse). As a result, a resistance value of the metal wiring becomes uniform, and thus it is difficult to obtain a desired high-frequency characteristic. 
     Therefore, controller  102  executes smoothing to reduce or eliminate unevenness  91  by ejecting ultraviolet curable resin  76  again onto planarized surface  86 A of insulating layer  86 . In the second ejection process in S 19  in  FIG. 3 , controller  102  causes ink jet head  75  to eject ultraviolet curable resin  76  onto planarized surface  86 A (refer to  FIG. 8 ). A fine circle in  FIG. 8  schematically indicates unevenness  91 . In the following description, in a case where ultraviolet curable resin  76  in the first ejection process in S 11  is differentiated from ultraviolet curable resin  76  in the second ejection process in S 19 , ultraviolet curable resin  76  in S 19  will be referred to as second ultraviolet curable resin  76 A. 
     Controller  102  sets an ejection amount of the second ultraviolet curable resin  76 A in S 19  to an amount corresponding to the size of unevenness  91 . Controller  102  causes inspection unit  24  to measures a height, a height difference, and the like of unevenness  91 , and automatically sets an ejection amount of second ultraviolet curable resin  76 A. For example, when the height of formed unevenness  91  is large (a groove is deep), controller  102  executes a process for increasing an ejection amount of ink jet head  75 . Alternatively, a user may manufacture a prototype of insulating layer  86 , measure a height or the like of unevenness  91 , and set the height or the like of unevenness  91  in control program  107 . Controller  102  may set an ejection amount of second ultraviolet curable resin  76 A based on information such as the height set in control program  107 . A method of adjusting an ejection amount of second ultraviolet curable resin  76 A may be performed not only by changing an ejection amount per unit area ejected from ink jet head  75 , but also by changing, for example, a size of liquid droplets ejected from ink jet head  75 , and the number of scans in which ink jet head  75  performs scanning on base plate  60  (base member  70 ) in one step in S 19 . Therefore, it is also possible to adjust an ejection amount of second ultraviolet curable resin  76 A to an optimal amount (an amount corresponding to the size of unevenness  91 ) by setting these three conditions in advance. 
     Therefore, in the second ejection process in S 19 , controller  102  of the present embodiment ejects second ultraviolet curable resin  76 A (an example of a second curable viscous fluid) in an ejection amount corresponding to the size of unevenness  91  formed on surface  86 A of insulating layer  86  (an example of a cured layer). According to this, in the second ejection process for performing smoothing, ejection is executed in an ejection amount corresponding to the size of unevenness  91  of surface  86 A of insulating layer  86  formed in the first curing process (S 15 ), for example, a height of unevenness  91 , a width of unevenness  91 , a height difference between unevenness  91 , or the like. Consequently, in the second ejection process, second ultraviolet curable resin  76 A is ejected in an appropriate amount, and thus unevenness  91  of surface  86 A of insulating layer  86  can be smoothed more effectively. Controller  102  may eject second ultraviolet curable resin  76 A in a constant ejection amount regardless of the size of unevenness  91 . Controller  102  may change an amount other than the ejection amount according to the size of unevenness  91 . For example, controller  102  may change the number of executions of S 19 , the number of scans of ink jet head  75 , and the like according to the size of unevenness  91 . For example, in a case where unevenness  91  is high (a groove is deep), controller  102  may increase the number of scans of ink jet head  75 . 
     Next, as illustrated in  FIG. 9 , controller  102  causes heater  82  to heat ejected second ultraviolet curable resin  76 A (heating process in S 21 ). Second ultraviolet curable resin  76 A of the present embodiment has a property that viscosity is reduced by being heated to improve fluidity. In a second curing process in S 23  described later, controller  102  cures second ultraviolet curable resin  76 A heated in the heating process in S 21 . That is, controller  102  heats second ultraviolet curable resin  76 A before curing second ultraviolet curable resin  76 A in a second curing process in S 23 . By heating second ultraviolet curable resin  76 A, it is expected to achieve an effect of reducing the viscosity of second ultraviolet curable resin  76 A and increasing the fluidity. Consequently, by increasing the fluidity of second ultraviolet curable resin  76 A, second ultraviolet curable resin  76 A easily spreads on the surface of unevenness  91 , and more easily enters a gap between unevenness  91 , and thus smoothing can be performed more effectively. 
     A method of heating second ultraviolet curable resin  76 A is not limited to heater  82  described above. For example, insulating layer  86  on which second ultraviolet curable resin  76 A is ejected may be placed in an atmosphere furnace, and second ultraviolet curable resin  76 A may be heated. Ink jet head  75  may heat second ultraviolet curable resin  76 A before being ejected in the nozzle and then eject heated second ultraviolet curable resin  76 A. 
     Next, controller  102  executes a curing process on heated second ultraviolet curable resin  76 A (S 23 ). That is, controller  102  executes the curing process on second ultraviolet curable resin  76 A without executing a planarization process using roller  79 . Controller  102  irradiates second ultraviolet curable resin  76 A ejected onto surface  86 A with ultraviolet light from irradiation device  81  to execute curing (refer to  FIG. 6 ). Consequently, as illustrated in  FIG. 10 , second ultraviolet curable resin  76 A ejected on surface  86 A is spread over fine unevenness  91  of surface  86 A due to a leveling effect and is smoothed to form smooth surface  93 . The leveling effect as described herein is a phenomenon in which a surface area of a liquid is as small as possible by the surface tension. Depending on the viscosity of a liquid, a thin film made of second ultraviolet curable resin  76 A changes in thickness to be planarized (more uniform) over time. Second ultraviolet curable resin  76 A is applied and spread by being ejected onto surface  86 A so as to fill unevenness  91 . Second ultraviolet curable resin  76 A is irradiated with ultraviolet light to increase the viscosity, so that it is cured to fill unevenness  91 . Consequently, formed smooth surface  93  is a surface in which unevenness  91  is reduced or a surface in which unevenness  91  is eliminated. 
     Next, controller  102  determines whether a desired smooth surface  93  has been formed (S 25 ). For example, when the processes in S 19  to S 23  are repeatedly executed a preset number of times, controller  102  performs an affirmative determination in S 25  (S 25 : YES). In this case, controller  102  may form a layer (smooth surface  93 ) of second ultraviolet curable resin  76 A having a desired thickness and shape by performing a negative determination in S 25  up to a preset number of times (S 25 : NO) and repeatedly executing the processes in S 19  to S 23 . 
     A determination criterion in S 25  is not limited to a preset number of times. For example, controller  102  may measure a surface roughness of smooth surface  93  with inspection unit  24 , and may perform an affirmative determination in S 25  in a case where the surface roughness is equal to or less than a predetermined surface roughness. Alternatively, controller  102  may automatically detect the number of repetitions of S 19  to S 23  in which the surface roughness is equal to or less than a desired surface roughness by experimentally forming smooth surface  93 . Controller  102  may set the number of times used in S 25  such that S 19  to S 23  are executed the number of times detected in advance, that is, the number of times in which the desired surface roughness is equal to or less than a desired surface roughness. 
     Controller  102  may change, for example, a size of liquid droplets of ultraviolet curable resin  76  ejected in S 11  and a size of liquid droplets of second ultraviolet curable resin  76 A ejected in S 19 . That is, controller  102  may execute ejection of multiple ultraviolet curable resins  76  at a time according to a so-called multi-drop method. Consequently, it is possible to more effectively perform smoothing due to a difference between liquid droplets. 
     Therefore, controller  102  may make a size of liquid droplets of second ultraviolet curable resin  76 A ejected in the second ejection process in S 19  different from a size of liquid droplets of ultraviolet curable resin  76  (an example of a first curable viscous fluid) ejected in the first ejection process in S 11 . According to this, by increasing a size of liquid droplets of second ultraviolet curable resin  76 A compared with a size of liquid droplets of ultraviolet curable resin  76 , it is possible to relatively increase the size of liquid droplets of second ultraviolet curable resin  76 A compared with a size, a height, or the like of unevenness  91 . Second ultraviolet curable resin  76 A can be applied and spread in a wider range to improve the efficiency of the smoothing process. Conversely, by reducing a size of liquid droplets of second ultraviolet curable resin  76 A compared with a size of liquid droplets of ultraviolet curable resin  76 , second ultraviolet curable resin  76 A can easily enter a gap between unevenness  91 , and thus smoothing can be performed more effectively. Controller  102  may make a size of liquid droplets of ultraviolet curable resin  76  in S 11  and a size of liquid droplets of second ultraviolet curable resin  76 A in S 19  the same as each other. 
     Next, when the layer (smooth surface  93 ) of second ultraviolet curable resin  76 A having a desired thickness or shape is formed (S 25 : YES), controller  102  forms a metal wiring on smooth surface  93 . Controller  102  forms a metal wiring at a predetermined position on smooth surface  93 , for example, based on three-dimensional data of control program  107 . Specifically, in a third ejection process in S 27 , controller  102  controls ink jet head  75  to eject metal ink  77  in a thin film form on smooth surface  93  of insulating layer  86  (refer to  FIG. 11 ). In the third curing process in S 29 , controller  102  causes heater  82  to heat and bake metal ink  77  ejected on smooth surface  93  (refer to  FIG. 12 ). In S 31 , controller  102  determines whether metal wiring  95  having a desired thickness or shape has been formed. For example, controller  102  performs a negative determination in S  31  up to a preset number of times (S 31 : NO), and repeatedly executes S 27  and S 29  to form desired metal wiring  95 . Desired metal wiring  95  described herein is metal wiring  95  that satisfies a required thickness, shape, or electrical characteristics. When S 27  and S 29  are repeatedly executed up to the preset number of times, controller  102  performs an affirmative determination in S 31  (S 31 : YES), and executes S 33 . Consequently, it is possible to shape insulating layer  86  (wiring board) in which metal wiring  95  is formed on smooth surface  93 . 
     Here, when metal ink  77  is ejected and cured on surface  86 A on which unevenness  91  is formed to form metal wiring  95 , a thickness of metal wiring  95  is made nonuniform due to unevenness  91 . There is concern that failures such as an increase in a resistance value of metal wiring  95 , disconnection, and deterioration of high-frequency characteristic may occur. In contrast, in shaping device  10  of the present embodiment, metal wiring  95  having a more uniform thickness can be formed, for example, by reducing a thickness to fine unevenness  91  of surface  86 A and ejecting metal ink  77  onto reduced smooth surface  93 . As a result, the resistance value of metal wiring  95  can be reduced to a desired value, and thus the occurrence of disconnection can be suppressed. 
     Controller  102  forms an insulating layer  86  having an insulating property as a cured layer of the present application, and forms metal wiring  95  on smooth surface  93  as a conductor. According to this, it is possible to form metal wiring  95  having improved high-frequency characteristics on insulating layer  86  by making electrical resistance values uniform. 
     In S 33 , controller  102  executes other processes. For example, controller  102  controls mounting unit  23  such that an electronic component is disposed on insulating layer  86  to be connected to metal wiring  95 . Alternatively, controller  102  may execute the processes from S 11  again in a case where further shaping of insulating layer  86  and metal wiring  95  is necessary. Controller  102  may control inspection unit  24  to inspect a completed structure (such as insulating layer  86  on which electronic components are mounted). When S 33  is executed, controller  102  finishes the shaping process illustrated in  FIG. 3 . Consequently, a desired structure can be shaped. 
     According to the above embodiment, the following advantages can be achieved. Controller  102  of shaping device  10  executes the first ejection process (S 11 ) of ejecting ultraviolet curable resin  76 , the planarization process (S 13 ) of planarizing ultraviolet curable resin  76  ejected through the process in S 11  with planarization device  78 , and the first curing process (S 15 ) of curing ultraviolet curable resin  76  planarized through the process in S 13 . Controller  102  repeatedly executes S 11 , S 13 , and S 15  (S 17 : NO) to form insulating layer  86 . Controller  102  executes the second ejection process (S 19 ) of ejecting second ultraviolet curable resin  76 A onto surface  86 A of insulating layer  86 , and the second curing process (S 23 ) of forming smooth surface  93  on surface  86 A of insulating layer  86  by curing second ultraviolet curable resin  76 A ejected through the process in S 19  without planarizing second ultraviolet curable resin  76 A with planarization device  78 . Controller  102  executes the third ejection process (S 27 ) of ejecting metal ink  77  onto smooth surface  93 , and the third curing process (S 29 ) of curing metal ink  77  ejected through the process in S 27  to form metal wiring  95  on smooth surface  93 . 
     According to this, insulating layer  86  of which surface  86 A is planarized is formed by repeatedly executing the first ejection process (S 11 ), the planarization process (S 13 ), and the first curing process (S 15 ). Fine unevenness that cannot be eliminated by planarization device  78  may be formed on planarized surface  86 A of insulating layer  86 . Therefore, second ultraviolet curable resin  76 A is ejected onto surface  86 A of insulating layer  86 , and ejected second ultraviolet curable resin  76 A is cured without being planarized by planarization device  78 . Consequently, second ultraviolet curable resin  76 A ejected on surface  86 A of insulating layer  86  is spread over the fine unevenness of the surface of insulating layer  86  due to the leveling effect and is smoothed to form smooth surface  93 . 
     Here, in a case where a cured layer (such as insulating layer  86 ) is formed by repeatedly ejecting and curing the first curable viscous fluid (such as ultraviolet curable resin  76 ) without using planarization device  78  (that is, without executing the planarization step), a surface of the cured layer rises at the end part or boundary part thereof due to the influence of surface tension, and thus a wave-like surface is formed as a whole. As a result, when a fluid containing metal particles is ejected onto a surface of a cured layer to form a conductor, there is concern that the formed conductor may have a wavy shape, or the fluid may flow along the surface of the cured layer and thus a thickness may be made nonuniform, so that electrical characteristics deteriorate. 
     Therefore, in shaping device  10  of the present embodiment, insulating layer  86  (an example of a cured layer) having a constant thickness is formed while being planarized. Next, second ultraviolet curable resin  76 A is ejected onto surface  86 A of formed insulating layer  86  and cured without being planarized, and smooth surface  93  having no unevenness or less unevenness can be formed on planarized insulating layer  86 . By ejecting and curing metal ink  77  (an example of a fluid containing metal particles) onto smooth surface  93 , metal wiring  95  having a more uniform thickness (having higher electrical characteristics) can be formed on insulating layer  86 . 
     As illustrated in  FIG. 2 , controller  102  of control device  26  includes first ejection section  110 , planarization section  111 , first curing section  112 , cured layer forming section  113 , second ejection section  115 , second curing section  116 , third ejection section  117 , third curing section  118 , and heating section  119 . 
     First ejection section  110  and the like are, for example, processing modules realized by executing control program  107  in the CPU of controller  102 . First ejection section  110  and the like may be configured by hardware instead of software. 
     First ejection section  110  is a functional section that causes ink jet head  75  to eject the first curable viscous fluid. Planarization section  111  is a functional section that causes planarization device  78  to planarize the first curable viscous fluid ejected by first ejection section  110 . First curing section  112  is a functional section that causes curing section  74  to cure the first curable viscous fluid planarized by planarization section  111 . Cured layer forming section  113  is a functional section that repeatedly executes processes in first ejection section  110 , planarization section  111 , and first curing section  112  to form a cured layer. Second ejection section  115  is a functional section that causes ink jet head  75  to eject the second curable viscous fluid onto surface  86 A of the cured layer. Second curing section  116  is a functional section that forms smooth surface  93  on surface  86 A of insulating layer  86  by curing the second curable viscous fluid ejected by second ejection section  115  with curing section  74  without planarization by planarization device  78 . Third ejection section  117  is a functional section that causes ink jet head  75  to eject a fluid containing metal particles onto smooth surface  93 . Third curing section  118  is a functional section that causes curing section  74  to cure the fluid containing metal particles ejected by third ejection section  117  to form a metallic conductor on smooth surface  93 . Heating section  119  is a functional section that heats the second curable viscous fluid in the second ejection step. 
     In the above embodiment, curing section  74  is an example of a curing device. Ink jet head  75  is an example of an ejection device. Ultraviolet curable resin  76  is an example of a first curable viscous fluid. Metal ink  77  is an example of a fluid containing metal particles. Insulating layer  86  is an example of a cured layer. Metal wiring  95  is an example of a conductor. Controller  102  is an example of a control device. S 11  is an example of a first ejection step. S 13  is an example of a planarization step. S 15  is an example of a first curing step. The process of repeatedly executing S 11 , S 13 , and S 15  is an example of a cured layer forming step. The process in S 19  is an example of a second ejection step. The process in S 23  is an example of a second curing process. The process in S 27  is an example of a third ejection step. The process in S 29  is an example of a third curing step. The process in S 21  is an example of a heating step. 
     (3. Others) 
     The present disclosure is not limited to the above examples, and can be implemented in various forms in which various modifications and improvements are made based on the knowledge of those skilled in the art. The first curable viscous fluid and the second curable viscous fluid of the present application are not limited to ultraviolet curable resin  76 , and various curable viscous fluids that are cured by light, heat, or the like may be employed. Therefore, a method of curing the first curable viscous fluid and the second curable viscous fluid is not limited to ultraviolet light. The first curable viscous fluid and the second curable viscous fluid may be different types of curable viscous fluids. The fluid containing metal particles of the present application is not limited to metal ink  77  containing silver, and may employ a fluid containing another metal. In the above embodiment, the degree of smoothness is inspected by measuring a surface roughness of smooth surface  93  with inspection unit  24 , but an inspection method is not limited to this. For example, shaping device  10  may measure a resistance value of formed metal wiring  95  to determine the degree of smoothness (quality of shaped metal wiring  95 ). Controller  102  does not have to execute the heating process (S 21 ) of heating second ultraviolet curable resin  76 A. Controller  102  may cure second ultraviolet curable resin  76 A without heating. Controller  102  does not have to execute the other processes in S 33 . For example, controller  102  does not have to execute mounting of electronic components using mounting unit  23  or inspection of a structure using inspection unit  24 . In the above embodiment, shaping device  10  for manufacturing a wiring board is employed as a shaping device of the present disclosure, but the present disclosure is not limited to this. As a manufacturing device of the present disclosure, various manufacturing devices for forming a conductor on the first curable viscous fluid and the second curable viscous fluid may be employed. Sizes of liquid droplets of second ultraviolet curable resin  76 A and ultraviolet curable resin  76  may be the same. 
     REFERENCE SIGNS LIST 
       10  Shaping device,  26  Control device,  102  Controller (control device),  74  Curing section (curing device),  75  Ink jet head (ejection device),  76  Ultraviolet curable resin (first curable viscous fluid),  76 A Second ultraviolet curable resin (second curable viscous fluid),  77  Metal ink (fluid containing metal particles),  78  Planarization device,  86  Insulating layer (cured layer),  86 A Surface,  93  Smooth surface,  95  Metal wiring (conductor),  110  First ejection section (first ejection step),  111  Planarization section (planarization step),  112  First curing section (first curing step),  113  Cured layer forming section (cured layer forming step),  115  Second ejection section (second ejection step),  116  Second curing section (second curing step),  117  Third ejection section (third ejection step),  118  Third curing section (third curing step),  119  Heating section (heating step)