# US 2022/0274342 A1 · Method for manufacturing three-dimensional shaped object and three-dimensional shaping apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0274342 A1 - Document ID: US20220274342A1 - Status: Published application - Kind: A1 - Application number: 17/652,313 - Filed: 2022-02-24 - Published: 2022-09-01 - Earliest claimed: 2021-02-26 - Assignees: Seiko Epson Corporation - Applicants: Seiko Epson Corporation - Inventors: Eiji OKAMOTO; Akihiko TSUNOYA - Web page: https://patentgrep.com/patent/US20220274342A1 ## CPC - B29C 64/393: for controlling or regulating additive manufacturing processes - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B29C 64/209: Heads; Nozzles - 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 - 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 ## Abstract A method for manufacturing a three-dimensional shaped object is a method for manufacturing a three-dimensional shaped object by laminating a shaping layer. The method includes a selection step of selecting a fiber material corresponding to a thickness of the shaping layer from a plurality of types of fiber materials having different fiber diameters, and a shaping step of forming the shaping layer by discharging a shaping material that includes the fiber material selected in the selection step from a nozzle opening. ## Claims ### Claim 1 A manufacturing method for manufacturing a three-dimensional shaped object by laminating a shaping layer, the method comprising: a selection step of selecting a fiber material corresponding to a thickness of the shaping layer from a plurality of types of fiber materials having different fiber diameters; and a shaping step of forming the shaping layer by discharging a shaping material that includes the fiber material selected in the selection step from a nozzle opening. ### Claim 2 (depends on 1) The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the plurality of types of fiber materials include a first fiber material and a second fiber material having the fiber diameter larger than that of the first fiber material, and in the selection step, the first fiber material is selected when forming a first shaping layer, and the second fiber material is selected when forming a second shaping layer having a thickness larger than that of the first shaping layer. ### Claim 3 (depends on 2) The method for manufacturing a three-dimensional shaped object according to claim 2, wherein the shaping step includes: an outline area forming step of forming the shaping layer included in an outline area that forms an outline of the three-dimensional shaped object; and an internal area forming step of forming the shaping layer that is included in an internal area surrounded by the outline area and that has a thickness larger than that of the shaping layer included in the outline area, and in the selection step, the first fiber material is selected when forming the shaping layer included in the outline area, and the second fiber material is selected when forming the shaping layer included in the internal area. ### Claim 4 (depends on 3) The method for manufacturing a three-dimensional shaped object according to claim 3, wherein a thickness of a single shaping layer included in the internal area corresponds to a sum of the thicknesses of a plurality of the shaping layers that are included and laminated in the outline area. ### Claim 5 (depends on 1) The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the shaping step includes: a moving step of relatively moving a stage at which the shaping layer is formed and a nozzle unit having the nozzle opening; and an introduction control step of controlling an introduction speed, at which the fiber material selected in the selection step is introduced toward the nozzle opening, in accordance with a relative movement speed between the nozzle unit and the stage. ### Claim 6 (depends on 1) The method for manufacturing a three-dimensional shaped object according to claim 1, wherein the shaping step includes: a plasticizing step of plasticizing at least a part of a material to generate a plasticized material; and a generation step of generating the shaping material to be discharged from the nozzle opening by introducing the fiber material selected in the selection step into the plasticized material, and the plasticizing step includes, in a plasticizing apparatus that includes a flat screw that has a groove forming surface in which a groove portion is formed, a facing portion that has a facing surface facing the groove forming surface and that is formed with a communication hole communicating with the nozzle opening, and a heater that is configured to heat the flat screw or the facing portion, a step of supplying the material between the flat screw and the facing portion, and guiding the material to the communication hole while plasticizing at least a part of the material by a rotation of the flat screw and heating of the heater. ### Claim 7 (depends on 6) The method for manufacturing a three-dimensional shaped object according to claim 6, wherein the flat screw has at least one through hole that is opened at the groove forming surface and that communicates with the communication hole, and the generation step includes a step of generating the shaping material by introducing the fiber material selected in the selection step into the plasticized material through the through hole. ### Claim 8 (depends on 6) The method for manufacturing a three-dimensional shaped object according to claim 6, wherein the groove forming surface or the facing surface has at least one introduction groove that guides the fiber material selected in the selection step from a side of the flat screw or the facing portion to the communication hole, and the generation step includes a step of generating the shaping material by introducing the fiber material selected in the selection step into the plasticized material through the introduction groove. ### Claim 9 (depends on 1) The method for manufacturing a three-dimensional shaped object according to claim 1, further comprising: a cutting step of cutting the fiber material by operating a discharge amount control mechanism that is provided upstream of the nozzle opening and that is configured to control a discharge amount of the shaping material. ### Claim 10 (depends on 9) The method for manufacturing a three-dimensional shaped object according to claim 9, wherein the discharge amount control mechanism is driven by a motor, and the method includes a step of transmitting a driving force generated by the motor to a conveying unit of the fiber material to convey the fiber material. ### Claim 11 A three-dimensional shaping apparatus that manufactures a three-dimensional shaped object by laminating a shaping layer, the three-dimensional shaping apparatus comprising: a control unit configured to select a fiber material corresponding to a thickness of the shaping layer to be formed from a plurality of types of fiber materials having different fiber diameters; and a discharging unit configured to discharge a shaping material that includes the fiber material selected by the control unit from a nozzle opening under control of the control unit.