JP2015202634A - Apparatus and method for object molding and program - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an object molding apparatus which suppresses decrease of productivity of a three-dimensional molding object and prevents deterioration of strength.SOLUTION: An object molding apparatus includes means of laying a powdery material containing a material for a member in a molding vessel for molding of the member, means of applying a bonding agent onto the laid powdery material, means of laying the powdery material onto the applied bonding agent, means of detecting the overflow amount of the powdery material overflowing from the molding vessel, out of the material laid onto the bonding agent, means of determining whether or not the overflowing powdery material is laid again in the molding vessel and means of laying the overflowing powdery material again in the molding vessel when specified conditions are met.

Description

  The present invention relates to an object shaping apparatus, an object shaping method, and a program.

  There is a powder lamination method as a method of forming a material, which is a material of a prototype, into a powder form and solidifying the layers one by one using a laser or an adhesive. This means that one layer of fine powder is spread on a modeling table and cured by a method such as sintering with an adhesive or a laser, and the next layer is further modeled to obtain a molded product. It is a modeling method.

  In a three-dimensional modeling apparatus using such a powder lamination method, three-dimensional modeling is performed by repeating a process of laminating powders one by one and applying a binder liquid having an adhesion and fixing effect to the powder by an inkjet header. You can get things.

  Such a three-dimensional modeling apparatus includes a modeling tank that holds powder for applying the binder liquid, and a supply tank that holds the powder supplied to the modeling tank. When laminating one layer of powder, one layer of powder is supplied from the supply tank to the modeling tank and laid by a blade or a roller.

  In Patent Document 1, in the sub-powder additive manufacturing type three-dimensional modeling system, in order to lay the powder uniformly, powder is further added to fill the irregularities on the powder of one layer solidified by modeling. A technique for laying a cable is disclosed.

  However, in the three-dimensional modeling apparatus using the conventional powder lamination method, if one layer of powder is supplied and laid in the modeling tank, the powder may be excessive and overflow outside the modeling tank after laying. It was. The surplus of powder indicates that the powder is not laid uniformly in the modeling tank, and if the powder is laid unevenly, the strength of the three-dimensional structure decreases. there were.

  In order to solve this problem, the powder that has overflowed after laying the powder in the modeling tank is laid again in the modeling tank, thereby uniformly laying the powder. Thereby, it was possible to prevent a decrease in strength of the three-dimensional structure. However, in this method, since an extra step of re-laying the powder is performed, the stacking time for one layer with respect to the modeling tank becomes long, and there is a problem that productivity is lowered.

  In the technique disclosed in Patent Document 1, powders are uniformly laminated by re-laying the powder. However, since the modeling time is increased by performing re-laying, the problem that productivity is lowered has not been solved.

  Therefore, the present invention has been made in view of the above-described problems of the prior art, and by determining whether or not to re-lay the powder overflowing from the modeling tank based on a predetermined condition, three-dimensional modeling An object of the present invention is to provide an object shaping apparatus capable of suppressing a decrease in product productivity and preventing a decrease in strength.

  In order to solve the above-described problem, the object modeling apparatus according to the first aspect of the present invention includes means for laying a powdery material containing the material of the member in a modeling tank for modeling the member, and the laid powdery material. Among the means for applying the bonding agent from above the object, the means for laying the powdery material from above the applied bonding agent, and the powdery material laid from above the bonding agent, the modeling tank Means for detecting the overflow amount of the powdery material overflowing from the device, means for determining whether to lay the overflowing powdery material again in the modeling tank, and when the predetermined condition is satisfied, the overflowing powdery material Means for re-laying an object in the modeling tank.

  ADVANTAGE OF THE INVENTION According to this invention, while suppressing the productivity fall of a three-dimensional molded item, the object modeling apparatus which can prevent a strength fall can be obtained.

It is a perspective view showing the whole object modeling device composition concerning an embodiment of the present invention. It is a principal part enlarged view which shows the structure of the unit with which the powder lamination | stacking part of the object shaping apparatus which concerns on embodiment of this invention was equipped. It is a figure explaining powder supply and laying operation in a powder lamination part of an object shaping apparatus concerning an embodiment of the present invention. It is a functional block diagram which shows the structure of the various control parts and peripheral device mounted in the control board in the printing apparatus in the object modeling apparatus which concerns on embodiment of this invention. It is a figure explaining the data of each layer used for the three-dimensional structure of the object modeling apparatus which concerns on embodiment of this invention. It is a figure which shows the control flow of the powder lamination | stacking in the powder lamination | stacking part of the object shaping apparatus which concerns on embodiment of this invention. It is a figure which shows the flow of the feasibility judgment of relaying by the amount of overflow powder of the object shaping apparatus which concerns on embodiment of this invention. It is a figure which shows the flow of the feasibility judgment of relaying by the modeling cross section of the object modeling apparatus which concerns on embodiment of this invention.

  Next, embodiments for carrying out the present invention will be described in detail with reference to the drawings. In addition, in each figure, the same code | symbol is attached | subjected to the part which is the same or it corresponds, The duplication description is simplified thru | or abbreviate | omitted suitably.

  The present invention provides a powder laminating method for creating a three-dimensional structure by repeatedly laminating a powdery material containing material of a member for each layer and repeatedly applying a binder liquid to the powdery material with an inkjet header. The present invention relates to the used object shaping apparatus and has the following features.

  First, the amount of powder overflowing when the powder is laid in the modeling tank is detected. Then, this overflowing powder is laid again in the modeling tank. Furthermore, the feasibility of this re-laying is determined based on the shape of the three-dimensional object to be modeled and the modeling mode selected by the user.

  In short, when the powder overflows when laying the powder in the modeling tank, whether or not to re-lay the overflowed powder based on the amount of the overflowed powder, the shape of the three-dimensional object to be modeled, and the modeling mode selected by the user It is characterized by re-laying after judging whether. The features of the present invention will be described in detail with reference to the drawings.

  First, the whole structure of the object shaping apparatus which concerns on embodiment of this invention is demonstrated. FIG. 1 is a perspective view showing an overall configuration of an object shaping apparatus according to an embodiment of the present invention.

  As shown in FIG. 1, a three-dimensional modeling system 100 that constitutes an object modeling apparatus according to an embodiment of the present invention includes a cartridge (main tank) containing a binder liquid as a bonding agent and a sub tank disposed in a carriage. A supply unit 10 for supplying and mounting the binder liquid is provided. Moreover, the powder lamination part which lays and hold | maintains the powder solidified by discharging a binder liquid is provided. However, the present invention is not limited to this configuration, and the main tank and the sub tank may be integrated.

  Next, the principal part which shows the structure of the unit with which the powder lamination | stacking part of the object shaping apparatus which concerns on embodiment of this invention was equipped is demonstrated. FIG. 2 is an enlarged view of a main part showing the configuration of a unit provided in the powder stacking unit of the object shaping apparatus according to the embodiment of the present invention.

  In FIG. 2, there are a modeling tank 16 (FIG. 1) and a supply tank 17 (FIG. 1) in the powder lamination part. Sufficient powder is held in the supply tank 17 before modeling, and one layer of powder is laid from the supply tank 17 to the modeling tank 16 at the time of modeling, and the binder liquid is applied to a predetermined position of the modeling tank 16 from the inkjet header. Discharge. A supply tank stage 171 and a modeling tank stage 161 that can move up and down in the Z direction in FIG. 1 are provided below the supply tank 17 and the modeling tank 16. Furthermore, a recoater 18 for laying one layer of powder from the supply tank 17 to the modeling tank 16 at the time of modeling is provided. A method for supplying and laying powder from the supply tank 17 to the modeling tank 16 will be described with reference to FIG.

  The 3D modeling system 100 also includes a maintenance unit 11 that recovers the ejection performance of the nozzle surface, and a main power supply unit that performs power on / off control of the 3D modeling system 100. Since these are not essential parts of the present invention, the details of the maintenance unit 11 and the details of the power control of the main power supply unit will be omitted.

  The three-dimensional modeling system 100 includes a head driving motor (not shown), and allows the carriage 14 to move in the main scanning direction. Further, a unit motor for moving the powder stacking unit (not shown) that enables movement of the modeling tank stage 161 and the supply tank stage 171 of the modeling tank 16 and the supply tank 17 in the Z direction and movement of the modeling tank 16 and the supply tank 17 in the Y direction. It has. Further, the head unit is provided with an encoder sensor (not shown), and notifies the control unit 13 of movement position information in the main scanning direction.

  Next, powder supply and laying operations will be described in the powder stacking unit of the object shaping apparatus according to the embodiment of the present invention. FIG. 3 is a diagram for explaining powder supply and laying operations in the powder stacking unit of the object shaping apparatus according to the embodiment of the present invention.

  First, as shown in FIG. 3 (1), the powder at the modeling position is solidified as shown in FIG. 3 (2) by applying a binder liquid to a predetermined position of the modeling tank 16 by an inkjet header. Next, as shown in FIG. 3 (3), the supply tank stage 171 (FIG. 2) of the supply tank 17 is raised in the Z direction, and the modeling tank stage 161 of the modeling tank 16 is lowered in the Z direction. Then, as shown in FIG. 3 (4), by moving the recoater 18, the differential powder between the supply tank 17 and the modeling tank 16 moves to the modeling tank 16 and is laid on the modeling tank 16.

  At this time, if the powder overflows, the powder accumulates in the overflow powder tank 20. The modeling tank 16 and the supply tank 17 in the present embodiment have the same shape. In FIG. 3C, the modeling tank 16 and the modeling tank stage 161 and the supply tank stage 171 of the supply tank 17 are raised and lowered by the same distance. In theory, the powder never overflows. That is, the fact that the powder overflows when the powder is laid by moving the recoater 18 means that the powder is not laid uniformly. The overflow powder tank 20 is provided with a weight sensor (not shown), and the amount of powder accumulated in the overflow powder tank 20 can be detected.

  When overflow powder is detected by a weight sensor (not shown), the stage of the overflow powder tank 20 is raised in the Z direction as shown in FIG. 3 (5), and the recoater 18 is first moved as shown in FIG. 3 (6). The overflow powder is laid again in the modeling tank 16 by moving to the position. Finally, the stage of the overflow powder tank 20 is lowered in the Z direction as shown in FIG.

  However, when such re-laying is performed, the time of the layering process of the powder for one layer becomes long, so that the productivity of the three-dimensional modeling system decreases. Therefore, when the amount of overflow powder exceeds a certain threshold value, the uniformity of the laying powder is greatly lost, or the cross-sectional area of the shaped object is less than a certain threshold value, so it becomes thin (thin), and the predetermined strength is reduced. Re-laying will be done only when necessary. Thereby, it becomes possible to re-lay without reducing the productivity of the three-dimensional modeling system. By setting the threshold value of the overflow powder amount in advance, the user can adjust the weight ratio between the production speed and the strength in the three-dimensional modeling system.

  Next, configurations of various control units and peripheral devices mounted on a control board in the printing apparatus in the object shaping apparatus according to the embodiment of the present invention will be described. FIG. 4 is a functional block diagram showing configurations of various control units and peripheral devices mounted on a control board in the printing apparatus in the object shaping apparatus according to the embodiment of the present invention.

  The control unit 400 includes a CPU (Central Processing Unit) 401 that controls the entire printing apparatus such as printing control, motor drive control, maintenance and supply control. The control unit 400 also includes a ROM (Read Only Memory) 402 that stores programs executed by the CPU 401 and other fixed data. The control unit 400 further includes a RAM (Random Access Memory) 403 that temporarily stores image data and the like. In addition, the control unit 400 includes a rewritable nonvolatile memory NVRAM (Non Volatile RAM) 404 that retains data while the apparatus is powered off. In addition, the control unit 400 includes an ASIC (Application Specific Integrated Circuit) 406 that processes various signal processing and rearrangement on image data and other input / output signals for controlling the entire apparatus.

  A host I / F (Interface) 405 for transmitting and receiving data and signals to and from the host side is provided. In addition, the control unit 400 includes a discharge control unit 409. The ejection control unit 409 generates a drive waveform for driving the recording head 416 and outputs image data for selectively driving the pressure generating unit of the recording head 416 and various data associated therewith to the head driver 415. Further, a motor 1 control unit 410 is provided for controlling the movement of the carriage in the main scanning direction and the sub-scanning direction.

  Further, the control unit 400 includes an I / O (Input / Output) 407 for inputting a detection pulse from the linear encoder 429 and a detection signal from the overflow powder amount detection sensor 428. The control unit 400 receives print data or the like by the host I / F 405 via a cable or a network. Print data and the like are generated by a driver 417 of an information processing device such as a personal computer, an image reading device such as an image scanner, and a host device (information processing device, external device) such as an imaging device such as a digital camera.

  Then, the CPU 401 of the control unit 400 reads and analyzes the print data in the reception buffer included in the host I / F 405, performs necessary image processing, data rearrangement processing, and the like in the ASIC 406, and sends it to the ejection control unit 409. Forward. Also, image data and drive waveforms are output from the ejection control unit 409 to the head driver 415 at a required timing. The generation of dot pattern data for outputting an image may be performed by storing font data in the ROM 402, for example. Alternatively, the host-side driver 417 may develop the image data into bitmap data and transfer it to the image forming apparatus.

  A drive waveform generation unit (not shown) of the ejection control unit 409 includes a D / A converter and an amplifier that perform D / A (Digital / Analog) conversion on drive pulse pattern data stored in the ROM 402 and read out by the CPU 401. In addition, a drive waveform composed of one drive pulse or a plurality of drive pulses is output to the head driver 415.

  The head driver 415 drives the recording head 416 based on image data (dot pattern data) corresponding to one line of the recording head 416 input serially. Specifically, a drive pulse constituting a drive waveform provided from a drive waveform generation unit (not shown) of the ejection control unit 409 is selectively applied to the pressure generating means of the recording head 416.

  The head driver 415 includes, for example, a shift register that inputs a clock signal and serial data that is image data, and a latch circuit that latches a registration value of the shift register using a latch signal. The head driver 415 includes a level conversion circuit (level shifter) that changes the level of the output value of the latch circuit, an analog switch array (switch means) that is turned on / off by the level shifter, and the like. Then, a required drive pulse included in the drive waveform is selectively applied to the pressure generating means of the recording head 416 by controlling on / off of the analog switch array.

  Next, the data of each layer used for the three-dimensional structure of the object modeling apparatus according to the embodiment of the present invention will be described. FIG. 5 is a diagram illustrating data of each layer used for the three-dimensional structure of the object modeling apparatus according to the embodiment of the present invention.

  As shown in FIG. 5A, the slice data is created by converting shape data input by three-dimensional CAD (Computer Aided Design) into STL (Standard Triangulated Language) data. Then, the STL data is sliced into layers having a constant thickness, and slice data that is a cross-sectional view is created.

  At this time, the thickness to be sliced is basically equal to the thickness of one layer laminated in the powder lamination portion. And according to each slice data, a binder liquid is apply | coated with the inkjet header with respect to the predetermined powder of the modeling tank corresponding to the cross-sectional part of a three-dimensional object.

  Here, as shown in FIG. 5B, the smaller the cross-sectional area of the slice data, the weaker the strength because the three-dimensional object to be shaped is thinner or thinner. Therefore, the smaller the area of the cross-section of the slice data, the higher the strength of the three-dimensional object modeling must be prevented. Therefore, the necessity of laying the powder in the powder lamination portion uniformly increases. That is, when the area of the cross section of the slice data is small, it can be said that it is necessary to re-lay the overflow powder.

  Next, the control flow of powder lamination in the powder lamination part of the object shaping apparatus according to the embodiment of the present invention will be described. FIG. 6 is a diagram illustrating a control flow of powder stacking in the powder stacking unit of the object shaping apparatus according to the embodiment of the present invention.

  First, in the processing of step (hereinafter referred to as S) 101, the slice data for one layer described in FIG. 5 is read. And in the process of S102 and S103, each stage of the supply tank 17 and the modeling tank 16 is raised / lowered, and the difference powder produced by this is moved to the modeling tank 16 using the recoater 18 in the process of S104 and laid. At this time, the stages of the supply tank 17 and the modeling tank 16 are raised and lowered by an amount corresponding to the thickness of the layers to be stacked.

  In the process of S105, the modeling mode preset by the user is confirmed. If the speed priority mode is set, the process proceeds to S113, the recoater 18 is returned to the supply tank 17 without any control of the overflow powder, and S112. Move on to processing. When the quality priority mode is set, the process proceeds to S106, and the amount of powder overflowing from the modeling tank 16 is detected when the powder is laid.

  When the overflow powder is not detected in the process of S106, the process proceeds to the process of S113, the control of the overflow powder is not performed, the recoater 18 is returned to the supply tank 17, and the process proceeds to S112. When the overflow powder is detected, the process proceeds to S107, and it is determined whether or not the re-laying of the overflow powder can be performed based on the amount of the overflow powder and the area of the object cross section of the slice data at this time. . This point will be described in detail with reference to FIGS.

  In the process of S108, when performing re-laying, first, the stage of the overflow powder tank 20 is raised in the process of S109, and then the recoater 18 is returned to the supply tank 17 side in the process of S110. In the process of S111, The stage of the overflow powder tank 20 is lowered and returned. In the process of S112, a binder liquid is apply | coated to the modeling tank 16 with an inkjet header. Finally, it is confirmed whether or not modeling has been completed for all slice data (all layers) in the process of S114. If the modeling is not completed, the above processing flow is repeatedly executed for the next slice data, and if the modeling is completed, the process is terminated.

  Next, a flow for determining whether or not re-laying can be performed based on the amount of overflow powder of the object shaping apparatus according to the embodiment of the present invention will be described. FIG. 7 is a diagram illustrating a flow of determining whether or not re-laying can be performed based on the amount of overflow powder of the object shaping apparatus according to the embodiment of the present invention. This flow is a flow for explaining in detail the processing when determining whether or not to re-lay the overflow powder in the processing of S107 of FIG.

  First, in the process of S115, it is confirmed whether or not the overflow powder amount threshold is set by the user. When the threshold value is set, the set threshold value is acquired from the NVRAM 404, and the amount of overflow powder generated in the current powder lamination in the processing of S116 is compared with the set threshold value. If it is equal to or greater than the threshold, the process proceeds to S118, and it is determined that re-laying is executed. If it is less than the threshold, the process proceeds to S119, and it is determined that re-laying is not executed.

  In the process of S115, when the overflow powder amount threshold is not set by the user, the default threshold (initial setting value) stored in the ROM 402 is acquired in advance, and the overflow powder generated in the current powder lamination in the process of S117 Compare the quantity with the default value. If it is equal to or greater than the initial setting value, the process proceeds to S120, and it is determined that re-laying is executed. When it is less than the initial set value, the process proceeds to S121, and it is determined that re-laying is not executed.

  Next, a flow for determining whether or not re-laying can be performed by the modeling cross-sectional area of the object modeling apparatus according to the embodiment of the present invention will be described. FIG. 8 is a diagram illustrating a flow of determining whether or not re-laying can be performed based on a modeling cross-sectional area of the object modeling apparatus according to the embodiment of the present invention. This flow is a flow for explaining in detail the processing when determining whether or not to re-lay the overflow powder in the processing of S107 of FIG.

  In the process of S122, it is confirmed whether the modeling cross-sectional area threshold is set by the user. When the threshold value is set, the setting threshold value is acquired from the NVRAM 404, and the modeling cross-sectional area of the current slice data is compared with the set threshold value in the process of S123. If it is less than the threshold value, the process proceeds to S125, and it is determined that re-laying is executed. If it is equal to or greater than the threshold, the process proceeds to S126, and it is determined that re-laying is not executed.

  In the process of S122, when the overflow modeling cross-sectional area threshold value is not set by the user, the default threshold value (initial setting value) stored in the ROM 402 in advance is acquired, and in the processing of S124, the modeling cross-sectional area of the current slice data and Compare with the default value. When it is less than the initial set value, the process proceeds to S127, and it is determined that re-laying is executed. If it is equal to or greater than the initial set value, the process proceeds to S128, and it is determined that re-laying is not executed.

  Each operation of the object shaping apparatus in the embodiment of the present invention shown in FIGS. 6 to 8 can be realized by a program on a computer. The control unit 400 of the object shaping apparatus loads a program stored in the ROM 402. Then, each processing step of the program is performed sequentially.

  As described above, according to the present invention, it is possible to suppress the decrease in productivity of the three-dimensional structure and reduce the strength by determining whether to re-lay the powder overflowing from the modeling tank based on a predetermined condition. Object shaping apparatus, object shaping method, and program can be obtained.

  The present invention has been described above by the preferred embodiments of the present invention. While the invention has been described with reference to specific embodiments thereof, various modifications and changes can be made to these embodiments without departing from the broader spirit and scope of the invention as defined in the claims. is there.

DESCRIPTION OF SYMBOLS 10 Supply part 11 Maintenance part 12 Main scanning module 13,400 Control part 14 Carriage 15 Heater 16 Modeling tank 17 Supply tank 18 Recoater 19 Recoater roller 20 Overflow powder tank 100 Three-dimensional modeling system 161 Modeling tank stage 171 Supply tank stage 401 CPU
402 ROM
403 RAM
404 NVRAM
405 Host I / F
406 ASIC
407 I / O
408 Supply unit 409 Discharge control unit 410 Motor 1 control unit 411 Motor 2 control unit 412 Motor 3 control unit 413 Motor 4 control unit 414 Maintenance control unit 415 Head driver 416 Recording head 417 Driver 418 Motor 5 control unit 419 Motor 6 control unit 420 Cartridge 421 Maintenance unit 422 Carriage X axis direction movable part 423 Main scanning module Y axis direction movable part 424 Recoater Y axis direction movable part 425 Supply tank stage Z axis direction movable part 426 Modeling tank stage Z axis direction movable part 427 Overflow powder tank stage Z-axis direction movable part 428 Overflow powder amount detection sensor 429 Linear encoder

Japanese Patent No. 3584782

Claims (9)

Means for laying a powdery material containing the material of the member in a modeling tank for modeling the member;
Means for applying a bonding agent from above the laid powder;
Means for laying the powdery material on the applied bonding agent;
Among the powdery materials laid from above the bonding agent, means for detecting the overflow amount of the powdery material overflowing from the modeling tank,
Means for determining whether or not to lay the overflowing powder in the modeling tank again;
Means for re-laying the overflowing powdery substance in the modeling tank when a predetermined condition is satisfied.   The predetermined condition is that a modeling mode for modeling the member is one of a speed priority mode and a quality priority mode, and when the modeling mode is the quality priority mode, the means for laying again The object modeling apparatus according to claim 1, wherein the overflowing powdery material is laid again in the modeling tank.   The predetermined condition is whether or not the detecting means detects the overflow amount, and when the detecting means detects the overflow amount, the means for laying again the overflowing powdery material. The object modeling apparatus according to claim 1, wherein the object modeling apparatus is laid again in the modeling tank.   The predetermined condition is whether or not the overflow amount is equal to or greater than a preset threshold value, and when the overflow amount is equal to or greater than the preset threshold value, the means for re-laying the overflow powder The object shaping apparatus according to any one of claims 1 to 3, wherein the object is laid again in the modeling tank.   Even when the overflow amount threshold value is not set in advance, when the overflow amount is equal to or greater than an initial set value, the means for laying again lays the overflowing powdery material again in the modeling tank. The object shaping apparatus according to claim 4.   The predetermined condition is whether or not the cross-sectional area of the member to be shaped is equal to or greater than a preset threshold value, and when the cross-sectional area is less than the preset threshold value, the means for laying again is The object modeling apparatus according to any one of claims 1 to 3, wherein the overflowing powdery material is laid again in the modeling tank.   Even when the cross-sectional area threshold value is not set in advance, when the cross-sectional area is less than the initial setting value, the means for re-laying re-lays the overflowing powdery substance in the modeling tank. The object shaping apparatus according to claim 6. An object modeling method,
Laying a powdery material containing the material of the member in a modeling tank for modeling the member;
Applying a bonding agent from above the laid powdery material;
Laying the powdery material on the applied bonding agent;
Of the powdery material laid from above the bonding agent, detecting the overflow amount of the powdery material overflowing from the modeling tank;
Determining whether to lay again the overflowing powder in the modeling tank; and
When the predetermined condition is satisfied, the step of laying the overflowing powder again in the modeling tank;
A method for forming an object characterized by comprising: In the computer of the object modeling device,
A process of laying a powdery material containing the material of the member in a modeling tank for modeling the member;
A process of applying a bonding agent from above the laid powder,
A process of laying the powdery material on the applied bonding agent;
Among the powdery materials laid from above the bonding agent, a process of detecting the overflow amount of the powdery material overflowing from the modeling tank,
A process for determining whether or not to lay the overflowing powder in the modeling tank again;
When the predetermined condition is satisfied, a process of laying the overflowing powder again in the modeling tank;
A program to realize

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