JP2015181791A - Manufacturing system and manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing system and the like capable of simply manufacturing appliances.SOLUTION: A manufacturing system 1 is used to manufacture a face guard 20 for being worn on a wearer's face 10. The manufacturing system 1 comprises: a three-dimensional shape data acquisition device 3 for acquiring three-dimensional shape data 11 on a surface of the wearer's face 10; an information processing unit 5 for correcting the three-dimensional shape data 11; a 3D printer 7 for manufacturing a gypsum mold 12 for manufacturing the face guard 20 on the basis of the three-dimensional shape data 11; a molding device 9 for molding a seat 14 by using the gypsum mold 12; and the like.

Description

  The present invention relates to an orthosis manufacturing system and a manufacturing method.

  When it is necessary to play a game with a broken nasal bone or cheekbone, a face guard may be worn to protect the face. Even if it is not a fracture or the like, depending on the event, the face and the like are protected with a brace (see Patent Documents 1 to 4).

  In order to manufacture a device such as a face guard according to the shape of the wearer's face, etc., usually, the shape of the face of the wearer is taken using plaster and the like, and a three-dimensional shape such as the face is used using this die. The mold shown is manufactured, and resin or the like is molded using the mold.

  On the other hand, using a 3D printer as disclosed in Patent Document 5 is also conceivable as a general manufacturing method of the brace. For example, Patent Document 6 describes, as a method for producing a dental prosthesis, creating a dental model, reading this three-dimensional shape, and producing a dental prosthesis using a 3D printer.

JP 2009-178191 A JP 2007-181647 A Japanese Utility Model Publication No. 6-64685 JP 2004-65898 A Patent No. 4403384 JP 2012-24396 A

  When taking out a face mold when manufacturing equipment such as face guards, it is necessary to fill the wearer's nostrils and apply a separating material to the face, or to apply a plaster after securing a respiratory route. is there. In addition, it is necessary for the wearer to stay still while tolerating pain and the like at the time of mold making. In addition, when creating the brace, it was necessary to modify the mold, which was complicated.

  The method of Patent Document 6 also does not read the three-dimensional shape of a tooth that is an object to which a dental prosthesis is to be attached, but first produces a dentition model and reads the three-dimensional shape. The production of the prosthesis takes time, and it was necessary to take a dental mold from the patient in order to create a dental model.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a production system or the like that can easily produce a brace.

  1st invention for solving the subject mentioned above is a production system of an appliance to be attached to an object, for producing the appliance based on three-dimensional shape data obtained by measuring the surface of the object. A production system comprising a 3D printer for producing a mold or forming a material for the appliance.

  In the present invention, using a 3D shape data obtained by directly measuring the surface of an object on which a device is to be mounted, a mold or a device for manufacturing the device is manufactured by a 3D printer. As a result, the mold or the appliance can be directly manufactured from the three-dimensional shape data, so that the above-described mold making is not required, and the manufacturing process of the appliance is simplified.

It is preferable that the apparatus further includes a molding device that molds the material of the appliance using the mold.
Thereby, an orthosis can be manufactured using the type | mold manufactured with 3D printer.

It is desirable to further include an information processing device for modifying the three-dimensional shape data.
This makes it possible to perform operations on the data, which have been conventionally performed by directly modifying the mold, and make the production of the brace more efficient.

For example, the information processing apparatus modifies the three-dimensional shape data by causing a part of the three-dimensional shape data to protrude outside the object or to be recessed inside the object. Further, the three-dimensional shape data can be modified by expanding the three-dimensional shape data to a predetermined width outside the object.
Regarding the modification of 3D shape data, for example, by providing a part of the 3D shape data that does not come into direct contact with the object or by increasing the holdability of the device, depending on whether a part of the 3D shape data is projected or recessed. Is possible. Furthermore, by expanding the three-dimensional shape data by a predetermined width, it is possible to create three-dimensional shape data in consideration of the thickness of the brace material.

It is desirable to further include a three-dimensional shape data acquisition device that measures the surface of the object.
In the present invention, it is possible to eliminate discomfort during measurement by using a three-dimensional shape data acquisition device capable of measuring the three-dimensional shape of the surface of an object.

In the 3D printer, it is preferable to manufacture the mold by hardening gypsum powder with an adhesive.
Thereby, a mold having a strength suitable for forming a material can be manufactured at a low cost.

Moreover, it is desirable that the appliance is a face guard to be attached to the face.
The production of the face guard is particularly suitable for applying the present invention because it is a complicated operation as described above and often causes discomfort during molding.

  A second invention is a method of manufacturing a device to be attached to an object, wherein a 3D printer manufactures a mold for manufacturing the device based on three-dimensional shape data obtained by measuring the surface of the object. Or it is the manufacturing method characterized by shape | molding the raw material of the said brace.

  According to the present invention, it is possible to provide a production system or the like that can easily produce a brace.

Diagram showing production system 1 Flow chart showing the procedure of the production method The figure shown about modification of three-dimensional shape data 11 The figure which shows production of the plaster mold 12a Diagram showing production system 1a Flow chart showing the procedure of the production method The figure shown about modification of three-dimensional shape data 11

  Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[First Embodiment]
(1. Production system 1)
FIG. 1 is a diagram showing a production system 1 according to the first embodiment of the present invention. The production system 1 produces a face guard 20 as an appliance, and includes a three-dimensional shape data acquisition device 3, an information processing device 5, a 3D printer 7, a molding device 9, and the like.

  The three-dimensional shape data acquisition device 3 acquires three-dimensional shape data of the surface of the wearer's face 10 as an object on which the face guard 20 is to be worn. For example, a 3D scanner is used.

  The 3D scanner is not particularly limited as long as it can acquire 3D shape data. For example, a stereo method in which an object is photographed with a plurality of cameras and the three-dimensional shape of the object is measured from the images, or a laser is irradiated on the object from a predetermined direction, and the image is taken. There is an active stereo method for measuring the three-dimensional shape of an object. In addition, there is an optical radar method that measures the three-dimensional shape of an object from the time until the object is irradiated with a laser from a predetermined direction and the laser reflected by the object is received. These are non-contact methods for measuring a three-dimensional shape, but a contact type device for measuring a three-dimensional shape by moving a probe or the like along an object can also be used.

  The information processing device 5 is a general computer having a control unit, a storage unit, an input unit, a communication unit, etc., and modifies the three-dimensional shape data acquired by the three-dimensional shape data acquisition device 3 to produce a plaster mold 12. 3D shape data for this purpose. This three-dimensional shape data is converted into a predetermined data format such as polygon data, and slice data cut into a plurality of upper and lower layers is created.

  The 3D printer 7 manufactures the plaster mold 12 based on the three-dimensional shape data. For example, the 3D printer 7 spreads gypsum powder and repeats the process of spraying and solidifying the adhesive material on the gypsum powder from the nozzle head based on the above slice data in order from the lower slice data to the upper slice data. Thus, the solidified gypsum powder is laminated, and the gypsum mold 12 is manufactured based on the three-dimensional shape data. The gypsum mold 12 is also provided with holes (not shown) necessary for forming the sheet 14 described later.

  The forming device 9 forms a sheet 14 containing a thermoplastic resin that is a material of the face guard 20 along the plaster mold 12.

  Here, the plaster mold 12 is placed on the molding apparatus 9, and the sheet 14 in a heated and softened state is placed on the plaster mold 12. And the sheet | seat 14 is attracted | sucked through said hole provided in the gypsum mold 12 with the shaping | molding apparatus 9, and air is blown from above and it cools and hardens | cures, making the sheet | seat 14 contact | adhere along the gypsum mold 12. FIG. Thereby, the sheet 14 can be formed along the shape of the plaster mold 12.

(2. Manufacturing method of face guard 20 by manufacturing system 1)
Next, a manufacturing method of the face guard 20 by the manufacturing system 1 will be described with reference to FIG. FIG. 2 is a flowchart showing the procedure of the manufacturing method.

  In the present embodiment, first, the three-dimensional shape data acquisition device 3 acquires the three-dimensional shape data of the surface of the face 10 of the wearer of the face guard 20 (S11). The three-dimensional shape data is input to the information processing device 5. FIG. 3A shows an example of the three-dimensional shape data 11 acquired in S11 with a solid line. The horizontal axis x in FIG. 3A is the horizontal direction, and the vertical axis z is the vertical direction. In the figure, a cross section from the forehead to the chin is shown. The same applies to FIGS. 3B, 4B, 4C, 7A, and 7B.

  The information processing apparatus 5 modifies the three-dimensional shape data 11 according to the input of the operator and creates the three-dimensional shape data 11 for producing the plaster mold 12 (S12).

  This modification is performed, for example, in order to provide a portion of the face guard 20 that does not come into direct contact with the affected part, or to improve the holdability of the face guard 20. Conventionally, these operations have been performed by directly modifying the plaster mold, but in the present embodiment, operations corresponding to this are performed on the data.

  For example, in the case of a fracture of the nasal bone, the three-dimensional shape data 11 is obtained at the position of the nose as shown by 11 'in FIG. 3A so that the face guard 20 does not directly contact the nose and a gap is formed between the nose. Protrusively partially outward. On the contrary, since the face guard 20 is positively contacted at the position of the cheekbone or the temple and it is desired to improve the holdability, the three-dimensional shape data 11 is partially depressed inward at these positions. Note that the outside means the outside of the face 10 indicated by the three-dimensional shape data 11, and the inside means the opposite.

  An example of the modified three-dimensional shape data 11 is shown in FIG. As described above, the three-dimensional shape data 11 is converted into a predetermined data format, thereby creating slice data.

  The 3D printer 7 produces the gypsum mold 12 as described above based on the three-dimensional shape data 11 after the modification (S13). After the gypsum mold 12 is manufactured, the holes necessary for forming the sheet 14 are drilled. It is also possible to create the three-dimensional shape data 11 including the hole when the three-dimensional shape data 11 of S12 is modified, and to create the plaster mold 12 including the hole by the 3D printer 7.

  And the sheet | seat 14 is shape | molded by the shaping | molding apparatus 9 along the plaster mold 12 as mentioned above (S14). Thereafter, the portion of the face guard 20 of the molded sheet 14 is cut off, and further, the portion that hits the eyes or the like is removed in order to secure a field of view. Then, the face guard 20 is manufactured by attaching a necessary member, for example, a sponge for providing cushioning properties or a fastener such as a hook-and-loop fastener for fixing the face. The face guard 20 can be colored by printing or the like to be given a pattern or the like.

  As described above, according to the present embodiment, the 3D printer 7 is used to form the gypsum mold 12 for manufacturing the face guard 20 using the three-dimensional shape data 11 obtained by directly measuring the surface of the wearer's face 10 itself. The face guard 20 can be manufactured by forming the sheet 14 by the forming device 9 using the plaster mold 12. Since the plaster mold 12 can be manufactured directly from the three-dimensional shape data 11 in this way, the above-described molding is not required, and the manufacturing process of the face guard 20 is simplified.

  In addition, by modifying the three-dimensional shape data 11 by the information processing device 5, the work that has been performed by directly modifying the plaster mold 12 can be performed on the data, and the production of the face guard 20 is more efficient. Can be At this time, by projecting a part of the three-dimensional shape data 11 to the outside or indenting the inside, it is possible to provide the face guard 20 with a portion that does not directly contact the affected part or to improve the holdability of the face guard 20. .

  In this embodiment, the 3D shape data acquisition device 3 is a 3D scanner, particularly the non-contact 3D scanner that can measure the 3D shape of the surface of the face 10 in a non-contact manner. It is possible to eliminate discomfort.

  In addition, in the 3D printer 7, the gypsum mold 12 having strength suitable for forming the sheet 14 and the like can be manufactured at low cost by hardening the gypsum powder with an adhesive. However, it is also possible to use a metal or resin mold in place of the plaster mold 12, and in this case, the 3D printer 7 uses a metal or resin molding.

  For example, when creating a metal mold, the 3D printer 7 performs a process of spreading metal powder, irradiating a laser or the like from the head based on the slice data, and sintering the metal powder from the lower slice data. What is necessary is just to use what makes the type | mold based on three-dimensional shape data by laminating | stacking a metal repeatedly to upper slice data.

  When a resin mold is manufactured, the 3D printer 7 applies a UV (Ultra Violet) curable resin from the nozzle head based on the slice data and solidifies it with ultraviolet rays from the lower layer to the upper layer. What is necessary is just to use what laminates | stacks resin repeatedly, and what laminates | stacks resin repeatedly from the lower layer to the upper layer in the process of apply | coating molten resin from a nozzle head based on slice data.

  The gypsum mold 12 as described above can be finely adjusted by an operator and is effective as a customized product for personal use. However, the gypsum mold 12 is slightly fragile in order to replicate the face guard 20 and the like many times for mass production. There is also. In such a case, it is effective to use a metal mold or a resin mold as described above. For example, when a metal mold is used, it is suitable for mass production of simple shapes that do not require shape correction. On the other hand, when a resin mold is used, fine adjustment is not possible as much as gypsum, but it can be adjusted to some extent, and is suitable for mass production of complicated shapes.

  Moreover, this embodiment gave and demonstrated the example which manufactures the face guard 20 with which a face is mounted | worn as an orthosis. The manufacture of the face guard 20 is particularly suitable for applying the present invention because it is a complicated operation as described above and often causes discomfort during mold making.

  However, the orthosis is not limited to the face guard 20. For example, a protector attached to an arm or leg can be produced in the same manner, and can be applied to production of party goods such as masks. In addition, the brace is not limited to those worn by humans, but can be produced in the same manner by those worn on animals other than humans and plants such as trees.

  In this embodiment, the positive gypsum mold 12 representing the three-dimensional shape of the surface of the face 10 as a convex shape is manufactured, but FIG. 4A shows the three-dimensional shape of the surface of the face 10 as a concave shape. A negative plaster mold 12a as shown in FIG. In S14, the sheet 14 can be formed by bringing the sheet 14 into close contact with the inner surface of the plaster mold 12a.

  In this case, when the three-dimensional shape data 11 is modified in S12, the height of the three-dimensional shape data 11 acquired in S11 is inverted as indicated by 11a in FIG. 4B. Further, in consideration of the thickness of the sheet 14 and the like, three-dimensional shape data 11a 'is created by expanding the three-dimensional shape data 11a by a predetermined width in the normal direction toward the outside.

  Similarly to the above, at the position where it hits the affected part such as the nasal bone, the three-dimensional shape data 11a ′ partially protrudes outward as shown by 11a ″ so that the face guard 20 does not directly touch the affected part. In addition, at a position where the face guard 20 is to be positively brought into contact with the face, such as the position of the cheekbone or the temple, the three-dimensional shape data is partially depressed inwardly, as shown in FIG. The example of the three-dimensional shape data 11 after performing is shown.

[Second Embodiment]
Next, a second embodiment of the present invention will be described. The second embodiment will be described with respect to differences from the first embodiment, and description of similar points will be omitted.

  FIG. 5 is a diagram showing a production system 1a according to the second embodiment. This manufacturing system 1a is different from the first embodiment in that the face guard 20 is directly manufactured by the 3D printer 7 and the molding apparatus 9 is omitted.

  FIG. 6 is a flowchart showing a procedure of a method of manufacturing the face guard 20 by the manufacturing system 1a. 6 is the same process as S11 described above, but in S22, the information processing apparatus 5 modifies the three-dimensional shape data 11 in accordance with the input of the operator, and thereby the face guard 20 is manufactured. For this purpose, three-dimensional shape data 11 is created.

  For example, as shown in FIG. 7A, the three-dimensional shape data 11b is created by expanding the three-dimensional shape data 11 by a predetermined width in the normal direction toward the outside in consideration of the thickness of the sheet 14 and the like. Similarly to the above, at a position corresponding to the affected part such as the nasal bone, the three-dimensional shape data 11b can be partially protruded outward as indicated by 11b 'so that the face guard 20 does not directly touch the affected part. Conversely, the three-dimensional shape data 11b is slightly recessed inward at a position where the face guard 20 is to be actively brought into contact with the face, such as the position of the cheekbone or the temple.

  With respect to the data thus created, a portion necessary for manufacturing the face guard 20 is cut out, and a portion corresponding to an eye or the like is a cavity. FIG. 7B shows an example of the three-dimensional shape data 11 after the correction as described above. The three-dimensional shape data 11 is also converted into a predetermined data format as described above, thereby creating slice data.

  The 3D printer 7 forms the material of the face guard 20 as described above based on the corrected three-dimensional shape data 11 (S23).

  For example, when the face guard 20 is made of resin, the 3D printer 7 that performs molding using a UV curable resin or a molten resin as described above is used. After molding the UV curable resin or molten resin, the face guard 20 is manufactured by attaching necessary members. It is also possible to give a desired pattern to the face guard 20 by coloring the UV curable resin or the molten resin.

  Also in the second embodiment described above, the same effect as in the first embodiment can be obtained. Further, since the production of the plaster mold 12 is omitted, the face guard 20 can be produced more quickly. Furthermore, in the case of the second embodiment, there is an advantage that the weight can be reduced and the strength can be secured by forming the face guard 20 into a honeycomb structure by modifying the three-dimensional shape data 11. This is a difficult task when the sheet 14 is formed using the plaster mold 12 or the like as in the first embodiment. On the other hand, in the first embodiment, since the sheet 14 is formed using the gypsum mold 12 as in the prior art, there is an advantage that the work can be performed accurately by the skill of the operator.

  The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to such examples. It will be apparent to those skilled in the art that various changes or modifications can be conceived within the scope of the technical idea disclosed in the present application, and these are naturally within the technical scope of the present invention. Understood.

DESCRIPTION OF SYMBOLS 1, 1a; Production system 3; Three-dimensional shape data acquisition apparatus 5; Information processing apparatus 7; 3D printer 9; Molding apparatus 10; Faces 11, 11 ′, 11a, 11a ′, 11a ″, 11b, 11b ′; Shape data 12, 12a; plaster mold 14; sheet 20; face guard

Claims (9)

A production system for an orthosis to be attached to an object,
A production system comprising a 3D printer for producing a mold for producing the device or forming a material for the device based on three-dimensional shape data obtained by measuring the surface of the object.   The manufacturing system according to claim 1, further comprising a molding device that molds the material of the appliance using the mold.   The manufacturing system according to claim 1, further comprising an information processing device for modifying the three-dimensional shape data.   The information processing apparatus modifies the three-dimensional shape data by projecting a part of the three-dimensional shape data to the outside of the target object or denting the inside of the target object. The production system according to claim 3.   The manufacturing system according to claim 3, wherein the information processing apparatus modifies the three-dimensional shape data by expanding the three-dimensional shape data by a predetermined width outside the object.   The production system according to claim 1, further comprising a three-dimensional shape data acquisition device that measures the surface of the object.   The said 3D printer manufactures the said type | mold by hardening gypsum powder with an adhesive material, The manufacturing system in any one of Claims 1-6 characterized by the above-mentioned.   The production system according to claim 1, wherein the orthosis is a face guard attached to a face. A method for producing a brace to be attached to an object,
A manufacturing method, wherein a 3D printer manufactures a mold for manufacturing the appliance or a material of the appliance based on three-dimensional shape data obtained by measuring the surface of the object.