Patent Publication Number: US-2017368758-A1

Title: Three-dimensional shaping apparatus, method of controlling same, and shaped object of same

Description:
TECHNICAL FIELD 
     The present invention relates to a three-dimensional shaping apparatus, a method of controlling the same, and a shaped object of the same. 
     BACKGROUND ART 
     A three-dimensional shaping apparatus that manufactures a shaped object based on three-dimensional design data is known by, for example, Patent Document 1. As systems of this kind of three-dimensional shaping apparatus, various systems, such as an optical shaping method, a powder sintering method, an ink jet method, and a molten resin extrusion shaping method have been proposed and made into products. 
     As an example, in a three-dimensional shaping apparatus adopting the molten resin extrusion shaping method, a shaping head for discharging a molten resin that is to be a material of a shaped object is mounted on a three-dimensional moving mechanism, and the shaping head is moved in three-dimensional directions to laminate the molten resin while discharging the molten resin, thereby obtaining the shaped object. In addition, a three-dimensional shaping apparatus adopting the ink jet method also has a structure in which a shaping head for dripping a heated thermoplastic material is mounted on a three-dimensional moving mechanism. 
     In this kind of three-dimensional shaping apparatus, employing a plurality of materials in one shaped object is presented in several documents, for example. However, when generating this kind of shaped object that complexly employs a plurality of materials, there is a problem that joining between the differing plurality of materials is weak, and a possibility of interlayer peeling occurring is high. 
     PRIOR ART DOCUMENT 
     Patent Document 
     Patent Document 1: JP 2002-307562 A 
     DISCLOSURE OF INVENTION 
     Problem to be Solved by the Invention 
     The present invention has an object of providing a three-dimensional shaping apparatus that, even when generating a shaped object that complexly employs a plurality of materials, can strengthen joining between the differing materials. In addition, the present invention has an object of providing a method of controlling the three-dimensional shaping apparatus and of providing a shaped object of the three-dimensional shaping apparatus. 
     Means for Solving the Problem 
     A three-dimensional shaping apparatus according to the present invention includes: a shaping stage on which a shaped object is placed; an elevator section which is movable in at least a perpendicular direction with respect to the shaping stage; a shaping head which is mounted in the elevator section and receives supply of plural kinds of resin materials whose materials differ; and a control section that controls the elevator section and the shaping head. The control section controls the shaping head such that, in a first layer, first resin materials are continuously formed in a first direction and arranged with a gap between the first resin materials in a second direction intersecting the first direction, and second resin materials other than the first resin materials are continuously formed in the first direction and arranged in the gap the first resin materials being one of the plural kinds of resin materials, and the second resin material being one of the plural kinds of resin materials. The control section further controls the shaping head such that, in a second layer provided above the first layer, the first resin materials are continuously formed in a third direction intersecting the first direction and arranged with a gap between the first resin materials in a fourth direction intersecting the third direction, and the second resin materials are continuously formed in the third direction and arranged in the gap. As a result, the first resin materials formed in the first layer and the first resin materials formed in the second layer are joined in an up-down direction. Furthermore, the second resin materials formed in the first layer and the second resin materials formed in the second layer are joined in the up-down direction. 
     In addition, a shaped object according to the present invention is a shaped object that includes plural kinds of resin materials, and includes a first layer and a second layer. The first layer includes a portion where first resin materials are continuously formed in a first direction and arranged with a gap between the first resin materials in a second direction intersecting the first direction, and second resin materials other than the first resin materials are continuously formed in the first direction and arranged in the gap the first resin materials being one of the plural kinds of resin materials, and the second resin material being one of the plural kinds of resin materials. Moreover, the second layer provided above the first layer includes a portion where the first resin materials are continuously formed in a third direction intersecting the first direction and arranged with a gap between the first resin materials in a fourth direction intersecting the third direction, and the second resin materials are continuously formed in the third direction and arranged in the gap, the first resin materials being one of the plural kinds of resin materials, and the second resin material being one of the plural kinds of resin materials, whereby the first resin materials formed in the first layer and the first resin materials formed in the second layer are joined in an up-down direction, and, furthermore, the second resin materials formed in the first layer and the second resin materials formed in the second layer are joined in the up-down direction. 
     Moreover, a method of controlling a three-dimensional shaping apparatus according to the present invention is a method of controlling a three-dimensional shaping apparatus that includes a shaping head. In this method, the shaping head is controlled such that, in a first layer, first resin materials of plural kinds of resin materials are continuously formed in a first direction and arranged with a gap between the first resin materials in a second direction intersecting the first direction, and second resin materials other than the first resin materials are continuously formed in the first direction and arranged in the gap, the first resin materials being one of the plural kinds of resin materials. Next, the shaping head is controlled such that, in a second layer provided above the first layer, the first resin materials are continuously formed in a third direction intersecting the first direction and arranged with a gap between the first resin materials in a fourth direction intersecting the third direction, and the second resin materials are continuously formed in the third direction and arranged in the gap. As a result, the first resin materials formed in the first layer and the first resin materials formed in the second layer are joined in an up-down direction, and, furthermore, the second resin materials formed in the first layer and the second resin materials formed in the second layer are joined in the up-down direction. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  is a perspective view showing a schematic configuration of a three-dimensional shaping apparatus according to a first embodiment. 
         FIG. 2  is a front view showing a schematic configuration of the three-dimensional shaping apparatus according to the first embodiment. 
         FIG. 3  is a perspective view showing a configuration of an XY stage  12 . 
         FIG. 4  is a plan view showing a configuration of an elevator table  14 . 
         FIG. 5  is a functional block diagram showing a configuration of a computer  200  (control device). 
         FIG. 6  is a side view showing an example of a structure of a shaped object S formed by the present embodiment. 
         FIG. 7  is a perspective view showing an example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 8  is a process drawing showing manufacturing steps of the shaped object S shown in  FIGS. 6 and 7 . 
         FIG. 9  is a side view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 10  is a perspective view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 11  is a side view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 12  is a perspective view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 13  is a side view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 14  is a side view showing another example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 15  is a plan view showing an example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 16  is a plan view showing an example of a structure of the shaped object S formed by the present embodiment. 
         FIG. 17  shows a modified example of the shaped object S. 
         FIG. 18  shows a modified example of the shaped object S. 
         FIG. 19  shows a modified example of the shaped object S. 
         FIG. 20  is a flowchart showing a procedure of shaping by the three-dimensional shaping apparatus of the present embodiment. 
         FIG. 21  is a schematic view showing a procedure of shaping by the three-dimensional shaping apparatus of the present embodiment. 
         FIG. 22  shows a schematic configuration of a three-dimensional shaping apparatus according to a second embodiment. 
         FIG. 23  is a perspective view showing a schematic configuration of a three-dimensional shaping apparatus according to a modified example. 
         FIG. 24A  is a process drawing explaining another method for manufacturing the shaped object S. 
         FIG. 24B  is a process drawing explaining another method for manufacturing the shaped object S. 
         FIG. 24C  is a process drawing explaining another method for manufacturing the shaped object S. 
         FIG. 24D  is a process drawing explaining another method for manufacturing the shaped object S. 
         FIG. 25  shows a first specific example of the shaped object S. 
         FIG. 26  shows a second specific example of the shaped object S. 
         FIG. 27  shows a third specific example of the shaped object S. 
         FIG. 28  shows a fourth specific example of the shaped object S. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     Next, embodiments of the present invention will be described in detail with reference to the drawings. 
     First Embodiment 
     (Overall Configuration) 
       FIG. 1  is a perspective view showing a schematic configuration of a 3D printer  100  employed in a first embodiment. The 3D printer  100  includes a frame  11 , an XY stage  12 , a shaping stage  13 , an elevator table  14 , and a guide shaft  15 . 
     A computer  200  acting as a control device that controls this 3D printer  100  is connected to this 3D printer  100 . Moreover, a driver  300  for driving a variety of mechanisms in the 3D printer  100  is also connected to this 3D printer  100 . 
     (Frame  11 ) 
     As shown in  FIG. 1 , the frame  11  has a rectangular parallelepiped external form, for example, and includes a framework of a metal material such as aluminum. Four of the guide shafts  15 , for example, are formed in four corners of this frame  11 , so as to extend in a Z direction of  FIG. 1 , that is, a direction perpendicular to a plane of the shaping stage  10 . The guide shaft  15  is a linear member defining a direction that the elevator table  14  is moved in an up-down direction as will be mentioned later. The number of guide shafts  15  is not limited to four, and is set to a number enabling the elevator table  14  to be stably supported and moved. 
     (Shaping Stage  13 ) 
     The shaping stage  13  is a platform on which a shaped object S is placed, and is a platform where a thermoplastic resin discharged from a later-mentioned shaping head is deposited. 
     (Raising-and-Lowering Table  14 ) 
     As shown in  FIGS. 1 and 2 , the elevator table  14  is penetrated at its four corners by the guide shafts  15 , and is configured movably along a longitudinal direction (Z direction) of the guide shaft  15 . The elevator table  14  includes rollers  34 ,  35  that contact the guide shafts  15 . The rollers  34 ,  35  are installed rotatably in arm sections  33  formed in two corners of the elevator table  14 . These rollers  34 ,  35  rotate while making contact on the guide shafts  15 , whereby the elevator table  14  is enabled to move smoothly in the Z direction. In addition, as shown in  FIG. 2 , a drive force of a motor Mz is transmitted by a power transmission mechanism configured from the likes of a timing belt, a wire, and a pulley, whereby the elevator table  14  moves in certain intervals (for example, a pitch of 0.1 mm) in the up-down direction. The motor Mz is preferably the likes of a servomotor or a stepping motor, for example. Note that by employing an unillustrated position sensor to measure a position in a height direction of the actual elevator table  14  continuously or intermittently in real time, and making an appropriate correction, it is possible to configure such that positional precision of the elevator table  14  is raised. The same applies also to later-mentioned shaping heads  25 A,  25 B. 
     (XY Stage  12 ) 
     The XY stage  12  is placed on an upper surface of this elevator table  14 .  FIG. 3  is a perspective view showing a schematic configuration of this XY stage  12 . The XY stage  12  includes a frame body  21 , an X guide rail  22 , a Y guide rail  23 , reels  24 A,  24 B, the shaping heads  25 A,  25 B, and a shaping head holder H. The X guide rail  22  has its both ends fitted to the Y guide rail  23 , and is held slidably in the Y direction. The reels  24 A,  24 B are fixed to the shaping head holder H, and move in XY directions following movement of the shaping heads  25 A,  25 B held by the shaping head holder H. The thermoplastic resin that will be a material of the shaped object S is a string-shaped resin (filaments  38 A,  38 B) having a diameter of about 3 to 1.75 mm, and is usually held in a wound state in the reels  24 A,  24 B, but during shaping, is fed into the shaping heads  25 A,  25 B by a later-mentioned motor (extruder) provided in the shaping heads  25 A,  25 B. 
     Note that it is also possible to adopt a configuration in which the reels  24 A,  24 B are fixed to the likes of the frame body  21  without being fixed to the shaping head holder H, and are not made to follow movement of the shaping heads  25 . Moreover, although a configuration has been adopted in which the filaments  38 A,  38 B are fed in an exposed state into the shaping heads  25 , it is possible for the filaments  38 A,  38 B to be fed into the shaping heads  25 A,  25 B mediated by a guide (for example, a tube, a ring guide, and so on). Note that, as will be mentioned later, the filaments  38 A,  38 B are each configured from a different material. As an example, in the case that one is any of an ABS resin, a polypropylene resin, a nylon resin, or a polycarbonate resin, the other can be configured as a resin other than the any one of those resins. Alternatively, it is also possible to configure such that even if the filaments  38 A,  38 B are of a resin of the same material, kinds or proportions of materials of fillers included on their insides differ. That is, the filaments  38 A,  38 B preferably each have a different property, and, by their combination, allow characteristics (strength, and so on) of the shaped object to be improved. 
     Note that in  FIGS. 1 to 3 , the shaping head  25 A is configured so as to melt and discharge the filament  38 A, the shaping head  25 B is configured so as to melt and discharge the filament  38 B, and independent shaping heads are respectively prepared for the different filaments. However, the present invention is not limited to this, and it is possible to adopt also a configuration of the kind where only a single shaping head is prepared, and a plurality of kinds of filaments (resin materials) are selectively melted and discharged by the single shaping head. 
     The filaments  38 A,  38 B are fed from the reels  24 A,  24 B, via tubes Tb, to inside the shaping heads  25 A,  25 B. The shaping heads  25 A,  25 B are held by the shaping head holder H, and are configured movably along the X, Y guide rails  22 ,  23 , together with the reels  24 A,  25 B. Moreover, although illustration thereof is omitted in  FIGS. 2 and 3 , an extruder motor for feeding the filaments  38 A,  38 B downwardly in the Z direction is disposed inside the shaping heads  25 A,  25 B. Although the shaping heads  25 A,  25 B should be configured capable of moving, along with the shaping head holder H, keeping a constant positional relationship with each other in the XY plane, they may also be configured such that their positional relationship with each other may be changed even in the XY plane. 
     Note that although illustration thereof is omitted in  FIGS. 2 and 3 , motors Mx, My for moving the shaping heads  25 A,  25 B with respect to the XY table  12  are also provided on this XY stage  12 . The motors Mx, My are preferably the likes of servomotors or stepping motors, for example. 
     (Driver  300 ) 
     Next, details of a structure of the driver  300  will be described with reference to the block diagram of  FIG. 4 . The driver  300  includes a CPU  301 , a filament feeding device  302 , a head control device  303 , a current switch  304 , and a motor driver  306 . 
     The CPU  301  receives various kinds of signals from the computer  200 , via an input/output interface  307 , and thereby performs overall control of the driver  300 . The filament feeding device  302 , based on a control signal from the CPU  301 , issues to the extruder motors in the shaping heads  25 A,  25 B commands controlling a feed amount (push-in amount or saving amount) to the shaping heads  25 A,  25 B of the filaments  38 A,  38 B. 
     The current switch  304  is a switch circuit for switching a current amount flowing in a heater  26 . By a switching state of the current switch  304  being switched, a current flowing in the heater  26  increases or decreases, whereby temperature of the shaping heads  25 A,  25 B is controlled. Moreover, the motor driver  306 , based on a control signal from the CPU  301 , generates a drive signal for controlling the motors Mx, My, Mz. 
       FIG. 5  is a functional block diagram showing a configuration of the computer  200  (control device). The computer  200  includes a spatial filter processing section  201 , a slicer  202 , a shaping scheduler  203 , a shaping instruction section  204 , and a shaping vector generating section  205 . These configurations can be achieved by a computer program inside the computer  200 . 
     The spatial filter processing section  201  receives, from outside, master 3D data indicating a three-dimensional shape of the shaped object which is to be shaped, and performs various kinds of data processing on a shaping space where the shaped object will be formed based on this master 3D data. Specifically, as will be described later, the spatial filter processing section  201  has a function of dividing the shaping space into a plurality of shaped units Up (x, y, z) as required, and assigning to each of the plurality of shaped units Up property data indicating characteristics that should be given to each of the shaped units, based on the master 3D data. A necessity of division into shaped units and a size of the individual shaped units are determined by a size and shape of the shaped object S to be formed. For example, division into shaped units is not required in a case such as when a mere plate is formed. 
     The shaping instruction section  204  provides the spatial filter processing section  201  and the slicer  202  with instruction data relating to content of shaping. As an example, the following are included in the instruction data. These are merely an exemplification, and it is possible for all of these instructions to be inputted, or only some to be inputted. Moreover, it goes without saying that an instruction differing from matters listed below may be inputted. 
     (i) size of one shaped unit Up
 
(ii) shaping order of the plurality of shaped units Up
 
(iii) kinds of the plural kinds of resin materials used in the shaped units Up
 
(iv) combination ratios (combination ratios) of the resin materials of different kinds in the shaped units Up
 
(v) direction that resin materials of the same kinds are continuously formed in the shaped units Up (hereafter, called “shaping direction”)
 
     Note that the shaping instruction section  204  may receive input of the instruction data from an input device such as a keyboard or mouse, or may be provided with the instruction data from a storage device storing the shaping content. 
     Moreover, the slicer  202  has a function of converting each of the shaped units Up into a plurality of slice data. The slice data is sent to the later-stage shaping scheduler  203 . The shaping scheduler  203  has a role of determining the likes of a shaping procedure or the shaping direction in the slice data, based on the previously mentioned property data. Moreover, the shaping vector generating section  205  generates a shaping vector based on the shaping procedure and shaping direction determined in the shaping scheduler  203 . Data of this shaping vector is sent to the driver  300 . The driver  300  controls the 3D printer  100  based on the received data of the shaping vector. 
     In the three-dimensional shaping apparatus of the present embodiment, the control device  200  operates such that plural kinds of resin materials have a direction that the resin material is extended out (shaping direction) differing for each layer, based on a specified combination ratio of the plurality of resin materials. A structure of the shaped object S formed by the present embodiment is shown as an example in  FIGS. 6 and 7 . 
       FIG. 6  is a side view of the shaped object S manufactured by the three-dimensional shaping apparatus of the first embodiment, and  FIG. 7  is a perspective view thereof. As shown in  FIGS. 6 and 7 , in the three-dimensional shaping apparatus of the first embodiment, for example, plural kinds of resin materials R 1 , R 2  are employed to shape one shaped object S (in order to simplify explanation, mainly the case where two kinds of resin materials are used will be described below, but it goes without saying that three or more kinds of resin materials may be employed). 
     Moreover, in this first embodiment, the plural kinds of resin materials R 1 , R 2  are formed, having one direction as their longitudinal direction, with a certain combination ratio, in one layer. In the example of  FIGS. 6 and 7 , in a first layer (lowermost layer of  FIG. 7 ), for example, the combination ratio of the resin materials R 1 , R 2  is assumed to be 1:1 and longitudinal directions of each of the resin materials R 1 , R 2  are an X axis direction (first direction), and the resin materials R 1  and R 2  are formed continuously in the X axis direction, alternately, so as to be arranged along a direction (second direction) orthogonal to the X axis. On the other hand, in a second layer one layer higher than the first layer, the combination ratio of the resin materials R 1 , R 2  is assumed to be 1:1 similarly to in the first layer, but longitudinal directions of each of the resin materials R 1 , R 2  are assumed to be not the X axis direction of the first layer, but an axis (third direction) intersecting this, for example, a Y axis direction, and the resin materials R 1 , R 2  are arranged along the X axis direction (fourth direction). As is clear also from later-mentioned description, the number of resin materials, the combination ratios of the resin materials, and so on, shown in these  FIGS. 6 and 7  are merely an example, and may of course be variously changed according to required specifications of the shaped object, and so on. Moreover, there is no need for the structure of  FIGS. 6 and 7  to be repeatedly formed in an entirety of the shaped object S. Identical resin materials only may be formed in part of the shaped object S. 
     In this kind of shaped object S, the resin material R 1 , while extending in the first direction in one layer, extends in the second direction intersecting the first direction in a layer one higher than that one layer. As a result, the shaped object S has a structure (a so-called parallel cross structure) in which fellow resin materials R 1  are joined in an up-down direction at intersection positions of the resin materials R 1  in the first layer and the second layer. The resin materials R 2  also have a similar parallel cross structure and are joined in the up-down direction similarly at positions sandwiched by the resin materials R 1 . Due to this kind of structure, even supposing that a joining force (in a transverse direction) between the resin materials R 1  and R 2  of different kinds is weak, if a joining force (in a laminating direction) between identical resin materials in the above-mentioned kind of parallel cross structure is strong, then strength of the shaped object S can be configured sufficiently high. 
     Note that although  FIGS. 6 and 7  illustrate a structure where the resin materials R 1 , R 2  contact without a gap in one layer, the structure of the shaped object S is not limited to this. A gap may occur between the resin materials adjacent in a transverse direction in one layer. 
     Moreover, by using the resin materials R 1 , R 2  of different kinds combined in one shaped object S in this way, a shaped object combining characteristics of different kinds of resin materials can be provided. For example, it becomes possible also to have advantages of a first resin material and compensate for disadvantages of the first resin material by advantages of a second resin material. 
     A shaping procedure of the shaped object S shown in  FIGS. 6 and 7  will be described with reference to  FIG. 8 . First, in the first layer, as shown in  FIG. 8( a ) , the resin materials R 1  are formed with the X direction as their longitudinal direction, with an arrangement pitch of substantially 1:1. 
     Then, as shown in  FIG. 8( b ) , the resin materials R 2  are similarly formed with an arrangement pitch of substantially 1:1, so as to fill gaps of the resin materials R 1 . At this time, the resin material R 2  can be formed so as to fill the gap of two resin materials R 1 , along outer peripheral shapes of the resin materials R 1 . By doing so, joining between the resin materials R 1  and R 2  can be strengthened. 
     Next, in the second layer, as shown in  FIG. 8( c ) , the resin materials R 2  are formed with the Y direction as their longitudinal direction, with an arrangement pitch of substantially 1:1. 
     Then, as shown in  FIG. 8( d ) , the resin materials R 1  are similarly formed with an arrangement pitch of 1:1, so as to fill gaps of the resin materials R 2 . At this time, the resin material R 1  can be formed so as to fill the gap of two resin materials R 2 , along outer peripheral shapes of the resin materials R 2 . By doing so, joining between the resin materials R 1  and R 2  can be strengthened. 
     By repeating the above-mentioned procedure shown in  FIGS. 8( a ) to 8( d ) , the shaped object S of the above-mentioned parallel cross structure is completed. 
     Note that in  FIGS. 8( c ) and 8( d ) , it is configured such that in the second layer, the resin materials R 2  are formed ahead with a certain arrangement pitch, and the resin materials R 1  are then filled into gaps of the resin materials R 2 , and a forming order of the resin materials R 1 , R 2  is made different for the first layer and the second layer. Alternatively, it is possible to configure such that in all of the layers, a specific resin material (for example, the resin material R 1 ) is formed ahead, and another resin material (for example, the resin material R 2 ) is then filled into the gap. However, changing the forming order of the resin materials R 1 , R 2  for each layer enables joining of the resin materials in the up-down direction to be further strengthened, and is more preferable. 
     Although  FIGS. 6 and 7  illustrated the shaped object S where the combination ratio of the resin materials R 1  and R 2  was substantially 1:1, it goes without saying that the shaped object S manufactured by the present embodiment is not limited to this. For example, the combination ratio is not limited to 1:1, and another desired ratio may be set. For example,  FIGS. 9 and 10  show the case where the combination ratio of the resin materials R 1  and R 2  is 2:1. Furthermore, it is also possible for the combination ratio to be changed gradually or continuously in the laminating direction and/or a horizontal direction (within an identical layer). 
     The shaped object S where the combination ratio of the resin materials R 1 , R 2  is 2:1 can be formed by repeatedly forming two resin materials R 1  and one resin material R 2  as in  FIGS. 9 and 10 . However, it is not limited to this, and, as shown in  FIGS. 11 and 12 , for example, the combination ratio 2:1 can be obtained also by repeatedly forming four resin materials R 1  and two resin materials R 2 . A pattern of repetition of the resin materials R 1 , R 2  like in  FIG. 9  is expressed as a “2:1 repetition pattern”. Moreover, a case like in  FIG. 11  is expressed as a “4:2 repetition pattern”. Moreover, although illustration thereof is omitted, the case where, respectively, m at a time and n at a time of the resin materials R 1  and R 2  are repeatedly formed is expressed as an m:n repetition pattern. This repetition pattern is expressed by repetition pattern data PR which will be mentioned later. 
     Note that when the same resin material is formed continuously in one layer, although an approximately circular columnar shaped resin material can be continuously formed as in  FIGS. 9 and 11 , it is also possible for a plate shaped resin material to be formed as shown in  FIGS. 13 and 14 . 
     Moreover, in the above-mentioned example, the structure in one shaped unit Up (or, the structure of the shaped object S when division into shaped units is not performed) was described. When the shaped object S is divided into a plurality of shaped units Up, the shaped object S in one layer is configured as in  FIG. 15 , for example ( FIG. 15  is the case where the combination ratio is 1:1, but this is merely an example, and it goes without saying that a combination ratio other than that illustrated may be adopted). 
     As shown in  FIG. 15 , the shaping space may be divided into a plurality of shaped units Up as required. One shaped unit Up is further divided into a plurality of slice data, and shaping is performed for each single layer corresponding to the slice data. For example, when shaping of a first layer of one shaped unit Up finishes, next, shaping of a first layer of a shaped unit (for example, the shaped unit Up′ of  FIG. 15 ) adjacent to this shaped unit Up is started. 
     At this time, in one layer of the shaped unit Up, the resin materials R 1 , R 2  are formed having one direction (for example, the X direction) as their longitudinal direction so as to be adjacent to each other with a certain arrangement pitch, but in the adjacent shaped unit Up′, in the same layer, the resin materials R 1 , R 2  are formed continuously having a different direction (for example, the Y direction) as their longitudinal direction. This is repeated in each layer, whereby the structure like that shown in  FIGS. 6 and 7 , for example, is formed. 
     Note that regarding lamination of a plurality of layers, although each of the layers can be laminated parallelly in the Z direction as shown in  FIG. 15 , there may also be lamination in a form where the layers are misaligned in the XY directions as shown in  FIG. 16 , for example ( FIG. 16  exemplifies the case where there is misalignment by a half pitch at a time in each of the X direction and the Y direction). 
       FIGS. 17 to 19  show modified examples of the shaped object S. 
     In the shaped object S of  FIGS. 6 and 7 , in one layer, the resin materials R 1 , R 2  have a linear shape extending along one direction (the X direction or the Y direction), and in the layer one above that layer, the resin materials R 1 , R 2  have a linear shape extending in a direction orthogonal (with an intersection angle of 90 degrees) to this. However, instead, as shown in  FIG. 17 , for example, the intersection angle of the resin materials R 1 , R 2  in the upper and lower layers may also be set to an angle other than 90°. In the case of this structure, a joining area between identical resin materials in the upper and lower layers becomes larger compared to in the case of 90°, and strength of the shaped object S can be increased more compared to in the case of  FIGS. 6 and 7 . 
     Moreover, in the example of  FIGS. 6 and 7 , the resin materials R 1 , R 2  in each layer have a linear shape having a certain one direction as their longitudinal direction, but, instead, as shown in  FIG. 18 , for example, each of the resin materials R 1 , R 2  may have a wavy line shape whose axial direction has one direction as its longitudinal direction (in other words, formed continuously in one direction overall). 
     Moreover, center lines or envelopes of the wavy line shaped resin materials R 1 , R 2  of  FIG. 18  have a linear shape, but, as shown in  FIG. 19 , those center lines or envelopes themselves may have a wavy line shape. The resin materials R 1 , R 2  of this  FIG. 19  are also formed so as to extend having one direction as their longitudinal direction overall. In other words, in the shaped object S of the present embodiment, identical resin materials should be formed so as to intersect each other in the upper and lower layers, and should have a shape by which they are joined at those intersections. 
     Next, a specific shaping procedure of the shaped object S employing the three-dimensional shaping apparatus of the present embodiment will be described with reference to the flowchart of  FIG. 20  and the schematic view of  FIG. 21 . 
     First, the computer  200  receives the master 3D data relating to a form of the shaped object S, from outside (S 11 ). Assumed here is a shaped object S of the kind shown on the left side of  FIG. 21 . The shaped object S illustrated in this  FIG. 21  is a triply structured spherical shaped object, and is configured from: an outer peripheral section Rs 1  configured mainly from the resin material R 1 ; an inner peripheral section Rs 2  in which the resin material R 1  and the resin material R 2  are mixed; and a central section Rs 3  configured mainly from the resin material R 2 . 
     The master 3D data includes: coordinates (X, Y, Z) at each configuring point of the shaped object S; and data (Da, Db) indicating the combination ratio of the resin materials R 1 , R 2  at the configuring point. Hereafter, data of each configuring point will be notated as Ds (X, Y, Z, Da, Db). Note that when there are three or more kinds of resin materials used, data Dc, Dd, . . . indicating the combination ratios of the relevant resin materials are added to the configuring point data Ds, in addition to the data Da, Db. 
     Moreover, the likes of a size Su of a shaped unit Us, shaping order data SQ indicating a procedure for shaping a plurality of the shaped units Us in one layer, resin data RU specifying the plural kinds of resin materials used, and repetition pattern data PR indicating how the plural kinds of resin materials are repeatedly formed (data indicating in what pattern the plural kinds of resin materials are formed), are outputted or instructed from the shaping instruction section  204  (S 12 ). At this time, part or all of necessary data is inputted to the shaping instruction section  204  from outside using an input device such as a keyboard or mouse, or is inputted to the shaping instruction section  204  from an external storage device. 
     Next, in the spatial filter processing section  201 , the shaping space indicated by the master 3D data is divided into a plurality of shaped units Up based on the instructed shaped unit size Su (S 13 ). As shown in  FIG. 21 , the shaped unit Up is a rectangular shaped space formed by dividing the shaping space of the shaped object S in the XYZ directions. 
     Each of the divided shaped units Up is assigned with property data reflecting the corresponding configuring point data Ds (X, Y, Z, Da, Db) (S 14 ). Whereas the master 3D data is continuous value 3D data indicating the shape of the shaped object S, data of each of the shaped units Up is discrete value 3D data indicating the shape of each of the shaped units Up. 
     Next, data of the shaped unit Up assigned with this kind of property data is sent to the slicer  202 . The slicer  202  further divides this data of the shaped unit Up along the XY plane, and generates a plurality of sets of slice data (S 15 ). The slice data is assigned with the previously mentioned property data. 
     Then, the shaping scheduler  203  executes density modulation on each of the slice data, based on the property data included in each of the slice data (S 16 ). Density modulation refers to a calculation operation that determines a forming ratio of the resin materials R 1  and R 2  in the relevant slice data, based on the previously mentioned combination ratio (Da, Db). 
     In addition, the shaping scheduler  203  determines the repetition pattern and the shaping direction of the resin materials R 1  and R 2 , based on a calculation result of the previously mentioned density modulation and on the shaping order data SQ and repetition pattern data PR received from the shaping instruction section  204  (S 17 ). In order to obtain the above-mentioned parallel cross structure, the shaping direction in the slice data of one layer is set to a direction orthogonal to that of the slice data in the layer one below that layer. 
     Then, the shaping vector generating section  205  generates a shaping vector, based on the shaping direction data determined in the shaping scheduler  203  (S 18 ). This shaping vector is outputted to the 3D printer  100  via the driver  300 , and a shaping operation based on the master 3D data is executed (S 19 ). Moreover, the plurality of shaped units Up are formed based on the shaping order data SQ instructed by the shaping instruction section  204 , and finally, the shaped object S is formed in the entire shaping space. 
     Advantages 
     As described above, due to the three-dimensional shaping apparatus of the present embodiment, shaping heads  24 A,  24 B are controlled such that in a first layer, plural kinds of resin materials are formed along a first direction, and the plural kinds of resin materials are aligned in a second direction intersecting the first direction. Moreover, the shaping heads  25 A,  25 B are controlled such that in a second layer provided above the first layer, the plural kinds of resin materials are formed along a third direction intersecting the first direction, and the plurality of kinds of resins are aligned in a fourth direction intersecting the third direction. As a result, in a shaped object, the plural kinds of resin materials are incorporated in a so-called parallel cross structure, and since there exist points where identical materials are in contact in a height direction, then, even when generating a shaped object that complexly employs a plurality of materials, joining between the differing plurality of materials can be comprehensively strengthened. 
     Moreover, using plural kinds of resin materials in one shaped object makes it possible to provide a shaped object combining advantages of the plural kinds of resin materials. For example, generally, in a material, strength and flexibility have conflicting characteristics, and development and production of a material combining the two is considered to be extremely difficult on a commercial scale. However, due to the shaping apparatus of the present invention, by configuring a parallel cross structure employing, for example, a resin material R 1  of high strength and a resin material R 2  of high flexibility, it is possible to achieve a resin material of high strength and high flexibility. 
     Moreover, by making variable a configuring ratio of the resin material R 1  and the resin material R 2 , it is also possible for the strength and flexibility characteristics to be made freely variable. 
     Moreover, regarding density of a material for which only discrete values could be achieved in conventional technology, a material density of continuous values can be achieved. 
     Moreover, a mixed material of fellow materials whose specific gravities differ greatly which conventionally could only be achieved in a gravity-free state such as outer space, can also be achieved by this shaping apparatus. 
     Second Embodiment 
     Next, a three-dimensional shaping apparatus according to a second embodiment of the present invention will be described with reference to  FIGS. 22 and 23 . The three-dimensional shaping apparatus of the second embodiment has an overall configuration and a basic operation and formable shaped object S that are similar to those of the first embodiment, hence duplicated descriptions thereof will be omitted below. 
     In this second embodiment, the structure of the shaping heads  25 A,  25 B is different from that of the first embodiment. 
     The shaping head  25 A of this second embodiment includes a plurality of (in the illustrated example, four) discharge holes NA 1 -NA 4  each aligned in a direction orthogonal to the shaping direction. The discharge holes NA 1 -NA 4  are given an arrangement pitch such that the resin materials R 1  respectively discharged therefrom are continuously aligned. That is, an opening diameter φ of each of the discharge holes NA 1 -NA 4  and a pitch P between adjacent discharge holes NA 1 -NA 4  determine an arrangement width of the continuously formed resin materials R 1 . 
     Similarly, the shaping head  25 B also includes a plurality of (in the illustrated example, four) discharge holes NB 1 -NB 4  each aligned in a direction orthogonal to the shaping direction. Note that the discharge holes NA 1 -NA 4 , NB 1 -NB 4  are controlled so as to be aligned in a direction orthogonal to a determined shaping direction, based on the shaping direction. 
     Employing this kind of shaping head makes it possible for shaping efficiency to be improved more compared to in the first embodiment. 
     [Other] 
     While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms: furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions. 
     For example, in the above-described embodiments, a moving mechanism of the 3D printer  100  includes: the guide shafts  15  extending perpendicularly to the shaping stage  13 ; the elevator table  14  that moves along the guide shafts  15 ; and the XY table  12 . However, the moving mechanism of the 3D printer  100  of the present invention is not limited to this. For example, it is possible to adopt a moving mechanism in which the XY table  12  where the shaping heads  25 A,  25 B are mounted is configured fixed, and the shaping stage  13  is configured able to be raised and lowered. In addition, for example, as shown in  FIG. 23 , the moving mechanism of the 3D printer  100  may include a multi-axis arm  41  having a fixed end on a bottom surface of the frame  11 . Moreover, a moving end (elevator section) of this multi-axis arm  41  may be mounted with shaping heads  25 A,  25 B similar to those of the previously mentioned embodiments. 
     Moreover, in the above-described embodiments, respectively independent configurations were shown for the 3D printer  100  and the computer  200  and driver  300 . However, it is also possible for the computer  200  and the driver  300  to be built in to the 3D printer  100 . 
     Moreover, the above-mentioned shaped object S is not limited to being manufactured by a three-dimensional shaping apparatus of the kind shown in the first and second embodiments.  FIGS. 24A to 24D  are process drawings showing other manufacturing steps of the above-mentioned shaped object S. As shown in  FIG. 24A , the resin materials R 1  and R 2  are bunched in parallel to each other, based on a certain arrangement order, and both ends thereof are fixed by fixtures  41 . Then, as shown in  FIG. 24B , a pressure-applying plate  42  and a heating plate  43  are placed on the resin materials R 1  and R 2  bunched in parallel to each other, and the resin materials R 1  and R 2  are heated to a certain temperature while being applied with pressure. As a result, the resin materials R 1  and R 2  bunched in parallel are rolled in a pressure-applying direction to attain a state of being joined to each other. This step shown in  FIG. 24B  is repeated a plurality of times, whereby a large number of resin plates in which the resin materials R 1  and R 2  have been rolled, are formed. 
     Next, as shown in  FIG. 24C , the large number of resin plates configured from the rolled resin materials R 1  and R 2  are laminated. At this time, the large number of resin plates are disposed such that, in two resin plates adjacent in the up-down direction, longitudinal directions of the resin materials R 1  and R 2  intersect each other. 
     Moreover, the pressure-applying plate  42  and the heating plate  43  are again placed on the large number of resin plates that have been laminated in this way, and these laminated resin plates are heated to a certain temperature while being applied with pressure. As a result, a shaped object S similar to that of the above-described embodiments is completed. 
     Note that it is also possible for the fixtures  41  to be omitted, provided that the resin materials R 1  and R 2  can be stably held. 
     Note that in any of the cases of the first embodiment, the second embodiment, and the embodiments of  FIGS. 24A to 24D , shaping may be performed while an adhesive agent (adhesive resin) or an adherence agent (surface treatment agent, surface modifying agent, or coupling agent) is being sprayed from outside. Now, an example of the adhesive agent (adhesive resin) is a material functioning to penetrate and fill a gap in an interface of the resin materials R 1  and R 2 . Moreover, an example of the adherence agent (surface treatment agent, surface modifying agent, or coupling agent) is a material functioning to activate surfaces such that a surface of the resin material R 1  or R 2  or surfaces of both the resin materials R 1 , R 2  have a functional group. By doing so, affinities with each other of the resin materials R 1  and R 2  increase and the resin materials R 1  and R 2  are strongly joined, hence even when the resin materials R 1  and R 2  are resins in a relationship that their affinities with each other are low, the resin materials R 1  and R 2  can be applied to an application where a breaking strength is required. 
     [Examples of Shaped Object S] 
     Various kinds of specific examples (applications) of the shaped object S generated based on the present embodiment will be described below. The shaped object S of the present embodiment may be used in a variety of applications, as will be described below. 
     First Specific Example 
     A first specific example of the shaped object S is shown in  FIG. 25 . In this first specific example, the shaped object S is applied as a material of a printed circuit board for an electronic circuit. 
     Generally, a glass epoxy resin combining a thermosetting resin and glass fiber is employed in a material of a printed circuit board. However, permittivity of glass fiber, at about 6.13, is extremely large. Therefore, there is a risk that the glass epoxy resin acts as a parasitic capacitance in a circuit mounted with the printed circuit board, that transmission loss or transmission delay increase particularly in a high frequency circuit, and that an error occurs. Note that although it is possible here to lower overall permittivity by mixing of a thermoplastic resin, a printed circuit board is required to have a heat resistance of about 140° C. in actual use, hence a mixing amount of the thermoplastic resin cannot be unconditionally increased. 
     In the first specific example, by having the following kind of structure, it is possible to provide a printed circuit board having high heat resistance while lowering permittivity. That is, as this first specific example, as shown in  FIG. 25 , a material of a low dielectric body, for example, polypropylene, polyterafluoroethylene (PTFE), or polychlorotrifluoroethylene (PCTFE) may be employed as the resin material R 1 . Moreover, a material excelling in heat resistance and rigidity, such as a polycarbonate or liquid crystal polymer, for example, may be employed as a material of the resin material R 2 . By selecting a combination of such materials and further appropriately setting the combination ratio of the resin materials R 1  and R 2 , it is possible to provide a shaped object of low permittivity and having appropriate heat resistance and rigidity. 
     As an example, by combining polypropylene and a liquid crystal polymer in a ratio of R 1 :R 2 =1:1, it is possible to provide a material whose permittivity is about 2.5 to 2.7. Particularly, when a liquid crystal polymer is employed as the resin material R 2 , it becomes possible for the printed circuit board to be used in a broadly ranged temperature region, since a thermal expansion coefficient of a liquid crystal polymer is extremely low and its rigidity is high. 
     Note that materials of the resin materials R 1 , R 2 , their combination ratios, and so on, may be arbitrarily selected based on required characteristics of the printed circuit board. 
     Second Specific Example 
     Next, a second specific example of the shaped object S is shown in  FIG. 26 . In this second specific example, the shaped object S is applied as an electromagnetic wave control element. 
     This shaped object S of  FIG. 26  is configured by combining the resin materials R 1  and R 2 , in addition to a main frame material R 0  acting as a framework of the shaped object S. The main frame material R 0  has a so-called parallel cross structure. That is, as shown in  FIG. 26 , a longitudinal direction of the main frame materials R 0  in a first layer and a longitudinal direction of the main frame materials R 0  in a second layer directly above the first layer intersect, and fellow main frame materials R 0  are joined in the up-down direction at their intersection positions. On the other hand, the resin materials R 1 , R 2  are formed so as to fill gaps of the main frame materials R 0  of this parallel cross structure. By the main frame material R 0  having a parallel cross structure in this way, it is made possible to provide an electromagnetic wave control element in which strength of the shaped object S overall is raised and that has desired characteristics due to the resin materials R 1 , R 2  filled into gaps thereof. 
     A polycarbonate resin, for example, may be used as a material of the main frame material R 0 . Note that there is no need for the parallel cross structure of the main frame R 0  to be formed over an entirety of the shaped object S, and that it is also possible to configure a shaped object S where partially the parallel cross structure does not exist as in  FIG. 26 . 
     Similarly to in the first specific example, a low dielectric body material such as polypropylene, polyterafluoroethylene (PTFE), or polychlorotrifluoroethylene (PCTFE) may be employed as the resin material R 1 . Moreover, a high dielectric body material such as polyvinylidene fluoride (PVDF) may be employed as the resin material R 2 . 
     By laminating the resin materials R 1 , R 2  alternately at certain intervals on the inside of the shaped object S and appropriately adjusting their combination ratios and arrangement pitches, it is possible to change electromagnetic wave attenuation characteristics possessed by the shaped object S. Specifically, since electric field-related refraction, reflection, and penetration change as the combination ratio or arrangement pitch changes for each layer or in-plane, a change in transmission length or change in vector direction of a polarization plane occurs, and attenuation characteristics of an electromagnetic wave can be adjusted. For example, by the arrangement pitch of the resin materials R 1  and R 2  changing, a degree of refraction or reflection with respect to the electric field at their interface changes, the transmission length changes, and an attenuation amount changes. Moreover, by the arrangement pitch in the laminating direction of the resin materials R 1  and R 2  changing, a phase of the electric field of a reflecting electromagnetic wave changes, whereby part of the electromagnetic wave is negated or weakened. Furthermore, by the combination ratio, and so on, of the resin materials R 1  and R 2  changing, a proportion of the electromagnetic wave changing to heat by negation due to phase change or a complex transmission path, also changes. Moreover, changing the combination ratio, and so on, of the resin materials R 1  and R 2  makes it possible to handle also a change in the electric field vector of the polarization plane of the electromagnetic wave, and to control the attenuation amount. 
     In this way, this second specific example makes it possible to provide an electromagnetic wave control element capable of controlling handling of attenuation characteristics of any electromagnetic wave regardless of polarization method or frequency, to a combination of the likes of refraction, reflection, or penetration of an electric field or a polarization plane. For example, it is possible to provide an electromagnetic wave absorbing body in any frequency (or any frequency band). Particularly, by three different permittivity materials being configured to change across multi-layers while having multiple kinds of in-plane configurations as in  FIG. 26 , negation due to reflection or attenuation due to extension of transmission length occurs in a plurality of modes, inside the shaped object S. As a result of this, the electromagnetic wave control element can function as an electromagnetic wave absorbing body not only in the case of a linearly polarized (vertically or horizontally polarized) electromagnetic wave, but even in the case of a circularly polarized or elliptically polarized electromagnetic wave. 
     Note that in this second specific example, it is also possible to omit the main frame material R 0  and form the shaped object S (electromagnetic wave control element) by the resin materials R 1  and R 2  only. 
     Third Specific Example 
     Next, a third specific example of the shaped object S is shown in  FIG. 27 . In this third specific example, the shaped object S is applied to a material of a sound wave absorbing element. 
     This shaped object of  FIG. 26  may also be similarly formed by laminating the resin materials R 1  and R 2  in a parallel cross structure. Note that, similarly to in the second specific example, it is also possible to add the main frame material R 0  that will be a framework of the shaped object S, in addition to the resin materials R 1  and R 2 . 
     When forming a sound wave absorbing element by the shaped object S, it is possible to employ a material whose rigidity is high but whose flexibility is poor and a material whose rigidity is low but whose flexibility is high, as the combination of resin materials R 1 , R 2 . As a result, a speed of sound waves changes at a boundary of the resin materials R 1  and R 2 , whereby sound waves are mutually cancelled out by a phase difference arising between the sound waves, and the sound waves are absorbed. As an example, a polycarbonate resin whose rigidity is high can be employed as the resin material R 1 , and a material whose flexibility is high such as an elastomer can be employed as the resin material R 2 . By adopting such a configuration, audible range sound waves or ultrasonic waves can be attenuated and suppressed, and, in effect, an element blocking these waves can be made. Moreover, by changing the pitch between layers, it is also possible to change a frequency being suppressed (or a frequency band being suppressed). Note that when the present sound wave absorbing element is applied to an enclosure of a canal type earphone (inner ear headphone), sound leakage can be prevented by absorption of sound waves to the outside while audible range sound waves are transmitted unhindered to inside of the ear. 
     Fourth Specific Example 
     Next, a fourth specific example of the shaped object S is shown in  FIG. 28 . In this fourth specific example, the shaped object S is applied to a material of an impact absorbing element. Conventionally, a foamed material whose flexibility is high or a gelled material has often been used as an impact absorbing element. However, the foamed material or gelled material has a problem that permeability is poor. The shaped object S of this fourth specific example makes it possible to provide an impact absorbing element solving the above-described problem of permeability, by having the following features. 
     This shaped object S of the fourth specific example of  FIG. 28  may also be similarly formed by laminating the resin materials R 1  and R 2  in a parallel cross structure. Note that, similarly to in the second specific example, it is also possible to add the main frame material R 0  that will be a framework of the shaped object S, in addition to the resin materials R 1  and R 2 . 
     When forming an impact absorbing element by the shaped object S, it is possible to employ a material whose rigidity is high and a material whose rigidity is low but whose flexibility is high, as the combination of resin materials R 1 , R 2 . As an example, a polycarbonate resin whose rigidity is high can be employed as the resin material R 1 , and a material whose flexibility is high such as an elastomer can be employed, acting as an elastic reinforcing material, as the resin material R 2 . Furthermore, in this fourth specific example, gaps in the parallel cross structure of the resin materials R 1  are not completely filled by the resin materials R 2 , and in parts, cavities AG are left. Such cavities AG can be formed with a desired density and arrangement pitch by adopting the manufacturing steps of the kind described by  FIG. 8 , for example. The fourth specific example configured in this way makes it possible to provide a shaped object S achieving coexistence of impact absorbing qualities and permeability. 
     DESCRIPTION OF REFERENCE NUMERALS 
     
         
         
           
               100  3D printer 
               200  computer 
               300  driver 
               11  frame 
               12  XY stage 
               13  shaping stage 
               14  elevator table 
               15  guide shaft 
               21  frame body 
               22  X guide rail 
               23  Y guide rail 
               24 A,  24 B filament holder 
               25 A,  25 B shaping head 
               31  frame body 
               34 ,  35  roller 
               38 A,  38 B filament 
               201  spatial filter processing section 
               202  slicer 
               203  shaping scheduler 
               204  shaping instruction section 
               205  shaping vector generating section