# US 12,005,506 B2 · Method for shaping three-dimensional shaped object

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- Number: US 12,005,506 B2
- Document ID: US12005506B2
- Status: Granted
- Kind: B2
- Application number: 16/802,076
- Filed: 2020-02-26
- Published: 2020-08-27
- Granted: 2024-06-11
- Earliest claimed: 2019-02-27
- Assignees: Seiko Epson Corporation
- Applicants: Seiko Epson Corporation
- Inventors: Kenta Anegawa; Daizo Aoyagi
- Web page: https://patentgrep.com/patent/US12005506B2

## CPC

- B22F 3/24: After-treatment of workpieces or articles {(B22F3/1146 takes precedence)}
- B22D 23/003: {Moulding by spraying metal on a surface}
- B22F 10/18: by mixing binder with metal in filament form, e.g. fused filament fabrication [FFF]
- B22F 10/22: Direct deposition of molten metal
- B22F 10/50: Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
- B22F 10/66: by mechanical means
- B22F 10/80: Data acquisition or data processing
- B22F 12/13: to preheat the material
- B22F 12/53: Nozzles
- B28B 1/001: {Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00)}
- B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
- B29C 64/188: involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control (surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00)
- B29C 64/209: Heads; Nozzles
- B29C 64/295: Heating elements
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 40/20: Post-treatment, e.g. curing, coating or polishing
- B22F 12/17: to heat the build chamber or platform
- B22F 2003/247: {Removing material: carving, cleaning, grinding, hobbing, honing, lapping, polishing, milling, shaving, skiving, turning the surface}
- B22F 2003/248: {Thermal after-treatment}
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y02P 10/25: Process efficiency
- 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
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B28B: SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER (foundry moulding B22C; working stone or stone-like material B28D; shaping of substances in a plastic state, in general B29C; making layered products not composed wholly of these substances B32B)
- 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)
- 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 method for shaping a three-dimensional shaped object using a cutting tool configured to perform cutting at a first length at maximum in a predetermined cutting direction, the method including: a first section shaping step of shaping a first section having a length in a first direction shorter than the first length by laminating a shaping material; a first section cutting step of cutting the first section with the cutting tool having a cutting direction along the first direction; a second section shaping step of shaping a second section having a length in a second direction shorter than the first length by laminating the shaping material, to connect to a first end surface of the first section in the first direction; and a second section cutting step of cutting the second section along the second direction with the cutting tool having a cutting direction along the second direction.

## Claims

### Claim 1

A method for shaping a three-dimensional shaped object using a cutting tool configured to perform cutting at a first length at maximum in a predetermined cutting direction, the method comprising:
generating cutting data, wherein the cutting data includes information on a rotation speed of the cutting tool and a feed speed of the cutting tool;
shaping a first rising portion on a stage;
shaping a first section having a tube shape in which an inner wall surface extends along a first direction, by laminating a shaping material in a laminating direction perpendicular to a shaping surface of the stage above the first rising portion, wherein
a portion of a length of the first section in the first direction is shorter than the first length,
the first direction corresponds to a direction along the shaping surface of the stage, and
an inclination angle of a first end surface of the first section with respect to the stage, on which the shaping material is laminated, is smaller than an inclination angle of a side surface of a nozzle, from which the shaping material is discharged, with respect to the stage;
cutting, based on the cutting data, the inner wall of the first section with the cutting tool having a cutting direction along the first direction;
heating, for a predetermined time, the first end surface of the first section after the cutting the inner wall of the first section;
shaping a second rising portion on the stage, wherein the second rising portion is shaped on the stage subsequent to the heating the first end surface;
shaping a second section having a tube shape in which an inner wall surface extends along a second direction, by laminating the shaping material in the laminating direction above the second rising portion and to connect to the first end surface of the first section in the first direction, wherein
a portion of a length of the second section in the second direction is shorter than the first length, and
the second direction corresponds to a direction along the shaping surface of the stage; and
cutting, based on the cutting data, the inner wall of the second section along the second direction with the cutting tool having a cutting direction along the second direction, wherein the predetermined time for heating the first end surface of the first section is set based on a type of the shaping material of the first section.

### Claim 2 (depends on 1)

The method for shaping the three-dimensional shaped object according to claim 1, wherein the first direction and the second direction are the same direction.

### Claim 3 (depends on 1)

The method for shaping the three-dimensional shaped object according to claim 1, wherein the first direction and the second direction are different directions.

### Claim 4 (depends on 1)

The method for shaping the three-dimensional shaped object according to claim 1, wherein at least one of a combined length of the inner wall of the first section and the inner wall of the second section in the first direction and a combined length of the inner wall of the first section and the inner wall of the second section in the second direction is longer than the first length.

### Claim 5 (depends on 1)

The method for shaping the three-dimensional shaped object according to claim 1, wherein an inclination angle of a third end surface of the first rising portion with respect to the stage is smaller than the inclination angle of the side surface of the nozzle with respect to the stage.

### Claim 6 (depends on 1)

The method for shaping the three-dimensional shaped object according to claim 1, wherein in the heating of the first end surface of the first section, a temperature of the first end surface of the first section is higher than a glass transition point of the shaping material.