Method of producing three-dimensionally shaped object and three-dimensional shaping apparatus

1. A method of producing a three-dimensionally shaped object, the method comprising:

a wall formation step of forming a wall by ejecting, from an ejection portion, a first fused thermoplastic resin onto a base stage while relatively moving the ejection portion with respect to the base stage to provide a space surrounded by the wall in a horizontal direction and open in an upward direction; and

an injection step of ejecting, from the ejection portion, a second fused thermoplastic resin under a controlled injection pressure from above the space so as to inject the second fused thermoplastic resin into the space,

wherein a viscosity of the second fused thermoplastic resin being ejected is lower than a viscosity of the first fused thermoplastic resin being ejected, and

wherein, in the injection step, a distal end surface of the ejection portion covers the space by coming into contact with a top surface of the wall, and a contact pressure equal to or larger than the injection pressure is applied between the distal end surface of the ejection portion and the top surface of the wall to improve a sealing property therebetween.

2. The method according to claim 1 ,

wherein the wall formation step is a step of forming the wall such that a plurality of the spaces each surrounded by the wall in the horizontal direction and open in the upward direction are provided, and

wherein the injection step is a step of sequentially performing said injecting of the second fused thermoplastic resin into each one of the plural spaces.

3. The method according to claim 1 , wherein the ejection portion comprises an ejection nozzle comprising the distal end surface provided with an air exhausting structure thereon, and

wherein, in the injection step, the second fused thermoplastic resin is injected into the space by using the ejection nozzle.

4. The method according to claim 1 ,

wherein the ejection portion comprises plural ejection nozzles, and

wherein, in the injection step, the second fused thermoplastic resin is ejected by using an ejection nozzle different from an ejection nozzle used in the wall formation step to eject the first fused thermoplastic resin, the different ejection nozzle comprising the distal end surface.

5. The method according to claim 1 , further comprising:

a step of storing, in a storage device, a three-dimensional model to be shaped;

a step of generating, by a computer, a framework portion model and a filling portion model based on the three-dimensional model;

a step of generating, by the computer and based on the framework portion model, a set of instructions for executing the wall formation step; and

a step of generating, by the computer and based on the filling portion model, a set of instructions for executing the injection step.

6. The method according to claim 1 , wherein the wall formation step is a step of forming the wall by ejecting, from the ejection portion, the first fused thermoplastic resin having a viscosity of 1100 Pa·S to 3000 Pa·S, and

wherein the injection step is a step of ejecting, from the ejection portion, and injecting, into the space, the second fused thermoplastic resin having a viscosity of 500 Pa·S to 1000 Pa·S.

7. The method according to claim 1 , wherein the wall formation step is a step of forming a portion constituting a surface of the three-dimensionally shaped object, and

wherein the injection step is a step of forming a filling portion of the three-dimensionally shaped object that is adjacent to the portion formed in the wall formation step.

8. The method according to claim 1 , wherein a temperature of the first fused thermoplastic resin ejected in the wall formation step is lower than a temperature of the second fused thermoplastic resin ejected in the injection step.

9. The method according to claim 1 , wherein the base stage is vibrated in the injection step.

10. The method according to claim 1 , wherein the contact pressure is selected so as not to deform the wall.

11. The method according to claim 1 , wherein the injection pressure is controlled so that the wall and the second fused thermoplastic resin are interconnected without any gap therebetween.

12. The method according to claim 1 ,

wherein, in the wall formation step, recess portions are formed between layers of the first fused thermoplastic resin forming the wall, and

wherein, in the injection step, the injection pressure is controlled so that the second fused thermoplastic resin fills the recess portions, thereby anchoring the second fused thermoplastic resin with the wall.