# US 11,305,481 B2 · Manufacturing method of three-dimensional object > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,305,481 B2 - Document ID: US11305481B2 - Status: Granted - Kind: B2 - Application number: 16/600,597 - Filed: 2019-10-14 - Published: 2020-04-16 - Granted: 2022-04-19 - Earliest claimed: 2018-10-15 - Assignees: Seiko Epson Corporation - Applicants: Seiko Epson Corporation - Inventors: Akihiko Tsunoya - Web page: https://patentgrep.com/patent/US11305481B2 ## CPC - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting - B22F 10/18: by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF] - B22F 10/38: to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures - B29C 64/20: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 50/02: for controlling or regulating additive manufacturing processes - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - B22F 10/43: characterised by material - B22F 12/10: Auxiliary heating means - B22F 12/33: translatory in the deposition plane - B22F 12/52: Hoppers - B22F 12/53: Nozzles - B22F 12/55: Two or more means for feeding material - B22F 2005/004: {Article comprising helical form elements (B22F5/085 takes precedence)} - B22F 2203/05: thermal expansion - B22F 2207/01: Composition gradients - B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy - Y02P 10/25: Process efficiency - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract Provided is a manufacturing method of a three-dimensional object for manufacturing a three-dimensional object by laminating unit layers using a fluid constituent material. The manufacturing method includes a unit layer formation step of forming the unit layer of one layer by forming a first unit layer in which first layers each having a first thickness are laminated and then forming a second unit layer formed of a second layer having a second thickness greater than the first thickness to adjoin the first unit layer. By executing such a manufacturing method of the three-dimensional object, it is possible to manufacture a highly dense three-dimensional object in a short time. ## Claims ### Claim 1 A method for manufacturing a three-dimensional object, the method comprising; forming a plurality of first unit layers on a plate, each first unit layer of the plurality of first unit layers being configured with a plurality of first layers that are stacked on each other in a first direction, each first layer of the plurality of first layers having a first thickness along the first direction, two adjacent unit layers of the plurality of first unit layers being spaced apart from each other via a space; forming a plurality of second unit layers in the spaces between the two adjacent unit layers of the plurality of first unit layers so as to form a first group of unit layers on the plate, each second unit layer of the plurality of second unit layers being configured by a single second layer, the single second layer having a second thickness in the first direction; and repeating the formation of the plurality of first unit layers and the formation of the plurality of second unit layers a plurality of times on a previously formed group of unit layers, wherein the second thickness is larger than the first thickness, and a first height in the first direction of each first unit layer of the plurality of first unit layers is equal to a second height in the first direction of each second unit layer of the plurality of second unit layers. ### Claim 2 (depends on 1) The method according to claim 1, wherein a first material for forming each first unit layer of the plurality of first unit layers is ejected from a ejector, and a second material for forming each second unit layer of the plurality of second unit layers is ejected from the ejector. ### Claim 3 (depends on 1) The method according to claim 1, wherein an outer most layer of the three-dimensional object is formed with only the plurality of first unit layers. ### Claim 4 (depends on 1) The method according to claim 1, wherein, when a first material for forming each first unit layer of the plurality of first unit layers is ejected from an ejector, the first material has a first viscosity, and when a second material for forming each second unit layer of the plurality of second unit layers is ejected from the ejector, the second material has a second viscosity that is smaller than the first viscosity. ### Claim 5 (depends on 4) The method according to claim 4, wherein, when the plurality of first unit layers are formed, the first material is heated by a heater at a first temperature, and when the plurality of second unit layers are formed, the second material is heated by the heater at a second temperature that is higher than the first temperature. ### Claim 6 (depends on 4) The method according to claim 4, wherein the first material and the second material are different from each other. ### Claim 7 (depends on 1) The method according to claim 1, wherein after the first group of unit layers is formed, a second group of unit layer is formed on the first group of unit layers, and the second group of unit layer is stacked on the first group of unit layers in the first direction, every first unit layer of the plurality of first unit layers in the second group of unit layers is formed on every second unit layer of the plurality of second unit layers in the first group of unit layers, and every second unit layer of the plurality of second unit layers in the second group of unit layers is formed on every first unit layer of the plurality of first unit layers in the first group of unit layers.