JP-2026076077-A - Materials for three-dimensional modeling, methods for three-dimensional modeling, and three-dimensional models.

Abstract

[Problem] To provide a three-dimensional molding material that can enhance the mechanical properties of three-dimensional objects. [Solution] A three-dimensional modeling material 1 used for creating three-dimensional objects, comprising a thermosetting resin 2 in a liquid phase and reinforcing fibers 3 dispersed in the thermosetting resin 2, wherein the reinforcing fibers 3 have a release-restricting portion 3a on their surface, and the release-restricting portion 3a bites into the cured thermosetting resin 2, thereby restricting the release of the reinforcing fibers 3 in the fiber direction. [Selection Diagram] Figure 1

Inventors

• 圓崎 諭
• 津田 雄一郎

Assignees

• 東レエンジニアリング株式会社

Dates

Publication Date

20260511

Application Date

20241023

Claims (7)

1. A three-dimensional modeling material used for creating three-dimensional objects, A thermosetting resin in liquid phase, The thermosetting resin contains reinforcing fibers dispersed within it. The reinforcing fiber has a shedding-restricting portion on its surface, The material for creating three-dimensional shapes is characterized in that the release-restricting portion prevents the reinforcing fibers from coming out in the fiber direction by biting into the hardened thermosetting resin.
2. The three-dimensional molding material according to claim 1, characterized in that the aforementioned shedding-restricting portion is a fuzzy portion formed by raising the surface of the reinforcing fiber.
3. The three-dimensional molding material according to claim 1 or 2, characterized in that the reinforcing fiber is carbon fiber, glass fiber, aramid fiber, or cellulose fiber.
4. The three-dimensional molding material according to claim 1 or 2, characterized in that the reinforcing fibers are milled fibers having an average fiber diameter of 2 to 20 μm and an average fiber length of 20 to 500 μm.
5. A method for creating a three-dimensional object using the three-dimensional molding material described in claim 1, The process includes a shell fabrication step in which the shell, which is the outer shell layer of the three-dimensional object, is fabricated using shell material, A core material filling step in which the three-dimensional molding material is filled as a core material in the core portion which is the part enclosed by the shell, A method for creating a three-dimensional object, characterized by including a core material hardening step of hardening the core material filled in the core portion.
6. A three-dimensional object formed using the three-dimensional molding material described in claim 1, The shell that forms the outer layer, A three-dimensional object characterized by comprising a core portion, which is the part enclosed by the shell, and a core molded portion, which is filled with the three-dimensional molding material and hardened.
7. The three-dimensional object according to claim 6, characterized in that at least a portion of the shell is removed and at least a portion of the core molded portion is exposed.

Description

This invention relates to a three-dimensional molding material, a three-dimensional molding method, and a three-dimensional molded object, and more particularly, to a three-dimensional molding material, a three-dimensional molding method, and a three-dimensional molded object used to create a three-dimensional molded object using additive manufacturing techniques such as 3D printing. The term "3D printer" is widely used to refer to manufacturing equipment that utilizes 3D printing technology. A 3D printer is a three-dimensional manufacturing device that uses 3D CAD data to calculate the cross-sectional shape of an object using a computer, divides the object into thin, slice-like cross-sectional components, forms these components using various methods, and then stacks them to create the desired object. Internationally, 3D printing technology is often used synonymously with "Additive Manufacturing Technology," and the Japanese translation used is "additive manufacturing technology." In recent years, 3D-printed objects are increasingly required to possess not only a desirable appearance but also rigidity and strength for pre-production evaluation of actual products. This has led to increased attention on metal 3D printers and composite material 3D printers. As one related technology, the applicant in this case proposes the three-dimensional fabrication method described in Patent Document 1 below. Patent Document 1 describes a three-dimensional molding method in which a shell layer, which will be the outer shell layer of a three-dimensional object, is fabricated in a molding tank where shell material is stored, and a core material is filled into the core portion, which is the inside of the fabricated shell layer, and this process is repeated multiple times in the layering direction, after which the core material is cured all at once by applying thermal energy. The core material is a thermosetting resin in which fibrous reinforcing material is dispersed. According to this three-dimensional molding method, since there is no layering interface in the hardened core material portion, it is possible to fabricate three-dimensional objects that do not have directional rigidity or strength. [Problems that the invention aims to solve] The applicant fabricated a three-dimensional object using the three-dimensional fabrication method described in Patent Document 1. A hardened core material of the fabricated object was used as a test specimen for a bending test, and the fracture surface after the bending test was observed. The results are shown in Figure 5. Figure 5 is a photograph of the fracture surface of the hardened core material, taken with a scanning electron microscope. As shown in the photograph 50 in Figure 5, multiple black holes 51 are formed across the entire fracture surface. These black holes 51 indicate the traces of fibrous reinforcing material 52 that have come loose. Multiple pieces of reinforcing material 52 are also visible exposed from the fracture surface, and gaps 54 are formed at the boundary between the exposed reinforcing material 52 and the resin 53. These gaps 54 indicate that the interface between the resin 53 and the reinforcing material 52 has delaminated. Observation of the fracture surface suggests that the following phenomenon occurs inside the fabricated object when external forces such as bending deformation are applied. Specifically, when an external force causing bending deformation is applied to the test specimen (hardened core material), a localized tensile force acts at the interface between the resin 53 and the reinforcing material 52. When this tensile force exceeds the allowable limit, the interface between the resin 53 and the reinforcing material 52 begins to delaminate, causing the reinforcing material 52 to slip. When this slippage of the reinforcing material 52 occurs, the aforementioned tensile force, i.e., the resistance to bending deformation, ceases to act. Furthermore, as the bending deformation increases, cracks propagate in the resin 53, causing fracture, and it can be inferred that the reinforcing material 52 present at the fracture surface detaches from the resin 53. Thus, although the three-dimensional objects produced by the three-dimensional printing method described in Patent Document 1 above are reinforced using reinforcing materials and have non-directional rigidity and strength, there was still room for further improvement to enhance their mechanical properties. Japanese Patent Publication No. 2019-136923 Means for solving the problem and their effects This invention has been made in view of the above-mentioned problems, and aims to provide a three-dimensional molding material, a three-dimensional molding method, and a three-dimensional molded object that can improve the mechanical properties of the three-dimensional molded object. To achieve the above objective, the three-dimensional molding material (1) according to the present invention is A three-dimensio