JP2020157761A - Three-dimensional object forming device, image processing method and program - Google Patents

Abstract

To provide a three-dimensional object forming device capable of forming a three-dimensional object that can be easily bent regardless of a bending direction.SOLUTION: There is provided a three-dimensional object forming device that comprises: a data receiving unit that receives three-dimensional image data of a three-dimensional object containing a plurality of layers; a data creation unit that creates three-dimensional formation data in which a portion located on a bending position designated as a bending position in the three-dimensional object is at least partially deleted from the three-dimensional image data; and a forming unit that forms the three-dimensional object based on the three-dimensional formation data, in which the data creation unit determines a width of the portion located on the bending position to be deleted from the three-dimensional image data based on a bending direction specified as the bending direction of the three-dimensional object at the bending position.SELECTED DRAWING: Figure 2

Description

The present invention relates to a three-dimensional object forming apparatus, an image processing method, and a program.

Conventionally, there has been known a three-dimensional object forming technique for forming a three-dimensional object by curing a layer formed of a material and stacking a plurality of layers. As a three-dimensional object forming technique, for example, a cured layer is formed by irradiating an ultraviolet curable resin ejected by an inkjet method with ultraviolet rays, or a cured layer is formed by sintering a powdery material. Various methods of doing so are known.

As an example, Patent Document 1 discloses a technique of ejecting an ink containing an energy ray-curable composition to a recording medium and irradiating the recording medium with energy rays to cure the ink on the recording medium. Since the energy ray-curable composition has stretchability, the cured film can be deformed following the recording medium.

However, when the recording medium on which the cured film is formed is bent, the cured film can stretch following the recording medium, but it is difficult to restore the cured film. Further, depending on the bending direction, it may be difficult to bend the recording medium.

The present invention has been made in view of the above, and an object of the present invention is to provide a three-dimensional object forming apparatus, an image processing method, and a program for forming a three-dimensional object that is easily bent regardless of the bending direction. To do.

In order to solve the above-mentioned problems and achieve the object, the three-dimensional object forming apparatus according to one embodiment of the present invention includes a data receiving unit that receives three-dimensional image data of a three-dimensional object including a plurality of layers, and the above. A data creation unit that creates three-dimensional formation data by deleting at least a part of a portion located on a bending position designated as a bending position in the three-dimensional object from the three-dimensional image data, and the three-dimensional formation. The data creation unit includes a forming unit that forms the three-dimensional object based on the data, and the data creating unit is based on the bending direction designated as the bending direction of the three-dimensional object at the bending position from the three-dimensional image data. It is characterized in that the width of the portion located on the bent position to be deleted is determined.

According to the present invention, there is an effect that a three-dimensional object that can be easily bent can be formed regardless of the bending direction.

FIG. 1 is a perspective view schematically showing an example of an image processing system according to the first embodiment. FIG. 2 is a cross-sectional view schematically showing a recording unit and a support unit according to the first embodiment. FIG. 3 is a block diagram functionally showing the image processing system according to the first embodiment. FIG. 4 is a diagram showing an example of a crease setting screen according to the first embodiment. FIG. 5 is a flowchart showing an example of the forming process of the modeled object in the first embodiment. FIG. 6 is a flowchart showing an example of a partial deletion process of print data according to the first embodiment. FIG. 7 is a cross-sectional view schematically showing the folded modeled object in the first embodiment. FIG. 8 is a cross-sectional view schematically showing a modeled object according to the second embodiment. FIG. 9 is a flowchart showing an example of a partial deletion process of print data in the second embodiment. FIG. 10 is a cross-sectional view schematically showing a bent modeled object in the second embodiment. FIG. 11 is a cross-sectional view schematically showing a part of the modeled object according to the third embodiment. FIG. 12 is a block diagram functionally showing the image processing system according to the fourth embodiment. FIG. 13 is a flowchart showing an example of image processing of print data of a modeled object according to the fourth embodiment. FIG. 14 is a block diagram showing an example of a schematic configuration of an image processing device and a control unit in each embodiment. FIG. 15 is a diagram showing an example of banding occurrence in a conventional three-dimensional model. FIG. 16 is a diagram showing an example of banding occurrence in a conventional three-dimensional model in which a bent portion is arbitrarily set. FIG. 17 is a block diagram functionally showing the image processing system according to the fifth embodiment. FIG. 18 is a flowchart showing the flow of the forming process of the modeled object in the fifth embodiment. FIG. 19 is a diagram showing an example of forming a modeled object in the fifth embodiment.

(First Embodiment)
Hereinafter, a three-dimensional object forming apparatus to which the present invention is applied, an image processing method, and a first embodiment of the program will be described with reference to FIGS. 1 to 7. FIG. 1 is a perspective view schematically showing an example of an image processing system 10 according to the first embodiment.

As shown in FIG. 1, in the following description, the X-axis, the Y-axis, the Z-axis, the X-direction, the Y-direction, and the Z-direction are defined. The X and Y axes extend horizontally and are orthogonal to each other. The Z axis extends vertically and is orthogonal to the X and Y axes. The X direction is a direction along the X axis and is also referred to as a main scanning direction. The Y direction is a direction along the Y axis and is also referred to as a sub-scanning direction. The Z direction is a direction along the Z axis and is also referred to as a vertical direction.

The image processing system 10 includes a three-dimensional object forming device 11 and an image processing device 12. The three-dimensional object forming device 11 and the image processing device 12 are connected by wire or wirelessly so as to be able to communicate with each other. The three-dimensional object forming device 11 includes a recording unit 21, a support unit 22, a drive unit 23, and a control unit 24. The recording unit 21 is an example of a forming unit.

FIG. 2 is a cross-sectional view schematically showing the recording unit 21 and the support unit 22 in the first embodiment. As shown in FIG. 2, the recording unit 21 of the present embodiment is arranged above the support unit 22, and an image or a three-dimensional object can be formed on the base material B supported by the support unit 22 by an inkjet method. .. The base material B is, for example, a recording medium.

The recording unit 21 has a plurality of nozzles 31 and a curing unit 32 that face the support unit 22 via an interval. The recording unit 21 records dots by ejecting the droplet D from the nozzle 31.

In this embodiment, the droplet D includes at least one of an ink droplet and an additional droplet. Ink droplets are droplets of ink containing a coloring material. That is, the ink droplets have a color. The additional droplets are, for example, white or transparent droplets. Further, the additional liquid drop model may have a color similar to that of the base material B.

Ink droplets and additional droplets are irritating and curable. The stimulus is, for example, light (ultraviolet rays, infrared rays, etc.), electron beam, heat, electricity, or the like. The ink droplets and additional droplets in the present embodiment have ultraviolet curability. The ink droplet and the additional droplet may have other stimulus curability such as thermosetting.

The curing unit 32 gives a stimulus for curing the droplet D to the droplet D discharged from the nozzle 31. The cured portion 32 in the present embodiment irradiates the droplet D discharged from the nozzle 31 with ultraviolet rays. The curing unit 32 is not limited to this example, and for example, when the droplet D has thermosetting property, the curing unit 32 heats the droplet D discharged from the nozzle 31.

The support portion 22 holds the base material B on the upper surface facing substantially vertically upward. The drive unit 23 in FIG. 1 relatively moves the recording unit 21 and the support unit 22 in the X, Y, and Z directions. The drive unit 23 has a first drive unit 35 and a second drive unit 36. The drive unit 23 may have either the first drive unit 35 or the second drive unit 36.

The first drive unit 35 moves the recording unit 21 in the X, Y, and Z directions. The second drive unit 36 moves the support unit 22 in the X, Y, and Z directions. The moving direction by the first driving unit 35 and the second driving unit 36 is not limited to this example. For example, the first drive unit 35 may move the recording unit 21 in the X and Y directions, and the second drive unit 36 may move the support unit 22 in the Z direction.

As shown in FIG. 2, the recording unit 21 has a configuration in which a plurality of nozzles 31 are arranged in a predetermined direction. Each nozzle 31 ejects ink droplets, additional droplets, or a mixed solution of ink droplets and additional droplets as droplet D. A known inkjet method can be used for the configuration of ejecting the nozzle 31 and the droplet D.

In this embodiment, the nozzles 31K, 31C, 31M, 31Y, 31W, and 31T are arranged in a predetermined direction. The nozzles 31K, 31C, 31M, and 31Y are nozzles 31 that eject ink droplets. Specifically, the nozzle 31K ejects black ink droplets, the nozzle 31C ejects cyan ink droplets, the nozzle 31M ejects magenta ink droplets, and the nozzle 31Y ejects yellow ink droplets. The nozzle 31W and the nozzle 31T are nozzles 31 that discharge additional droplets. Specifically, the nozzle 31W ejects a white additional droplet (white ink), and the nozzle 31T ejects a transparent additional droplet (clear ink).

The three-dimensional object forming device 11 ejects the droplet D from each nozzle 31 to form dots corresponding to the droplet D on the base material B, and forms a layer L having a plurality of dots. One layer L is also referred to as an image. Further, the three-dimensional object forming apparatus 11 forms the modeled object O by laminating a plurality of layers L by ejecting the droplet D at the same position a plurality of times. The modeled object O is an example of a three-dimensional object. As described above, the modeled object O formed by the three-dimensional object forming apparatus 11 includes a plurality of layers L. The three-dimensional object forming apparatus 11 may be capable of forming a modeled object O (single layer image) formed by one layer L.

In the example of FIG. 2, each nozzle 31 ejects a droplet D of one color (one type). However, each nozzle 31 may eject a mixed droplet of a plurality of types of droplet D. The color of the ink ejected from the recording unit 21 is not limited to black, cyan, magenta, and yellow, and may be another color. Further, the types of the liquid drops D discharged from the recording unit 21 are not limited to six types (black, cyan, magenta, yellow, white, transparent).

In the present embodiment, hardening portions 32 are provided at both ends of the nozzles 31K, 31C, 31M, 31Y, 31W, and 31T in the arrangement direction. The droplet D is cured by irradiating the droplet D discharged from each nozzle 31 with light from the curing portion 32.

The cured portion 32 is arranged in the vicinity of the nozzle 31. By arranging the cured portion 32 in the vicinity of the nozzle 31, the curing time from when the droplet D discharged from each nozzle 31 adheres to the base material B to when it is cured can be shortened, and a higher-definition model O Can be formed. The number of the cured portions 32 and the installation position of the cured portions 32 are not limited to the example of FIG.

The three-dimensional object forming apparatus 11 forms dots by the droplet D on the base material B by relatively moving the recording unit 21 and the base material B while discharging the droplet D from the nozzle 31 of the recording unit 21. It is possible. The base material B is, for example, sheet-shaped, but may be three-dimensional.

FIG. 3 is a block diagram functionally showing the image processing system 10 according to the first embodiment. The control unit 24 receives print data from the image processing device 12. The print data is an example of three-dimensional image data. The control unit 24 controls the recording unit 21 and the driving unit 23 according to the received print data, ejects the droplet D corresponding to each pixel from the nozzle 31, and cures the droplet D on the curing unit 32.

The control unit 24 is a computer configured to include a CPU (Central Processing Unit) and the like, and controls the entire three-dimensional object forming apparatus 11. The control unit 24 may be different from the configuration including a general-purpose CPU. For example, the control unit 24 may be configured by a circuit or the like.

The control unit 24 includes a data receiving unit 41, a discriminating unit 42, a conversion unit 43, a recording control unit 44, and a storage unit 45. The conversion unit 43 is an example of a data creation unit. Even if a part or all of the data receiving unit 41, the discriminating unit 42, the converting unit 43, and the recording control unit 44 are executed by a processing device such as a CPU, that is, by software. It may be realized by hardware such as IC (Integrated Circuit), or may be realized by using software and hardware together.

The data receiving unit 41 receives the print data of the modeled object O. The print data is information such as the shape and color of the modeled object O to be formed. The print data may include information on the formation method and material of the modeled object O. The print data is, for example, CAD / CAM data. The print data is not limited to this example.

The data receiving unit 41 acquires print data from the image processing device 12 via the communication unit. The data receiving unit 41 may acquire the print data from the storage unit 45 in which the print data is stored in advance.

When a crease is set in the modeled object O, the determination unit 42 and the conversion unit 43 create conversion data in which a part is deleted from the print data. The converted data is an example of three-dimensional formation data. The recording control unit 44 controls the recording unit 21 and the driving unit 23 based on the print data or the conversion data to form the modeled object O.

The image processing device 12 includes a control device such as a CPU, a storage device such as a ROM (Read Only Memory) and a RAM (Random Access Memory), an auxiliary storage device such as an HDD (Hard Disk Drive), and a CD drive device, and a display. It is equipped with a display device such as a device and an input device such as a keyboard and a mouse, and has a hardware configuration using a normal computer.

The image processing device 12 creates or stores print data, and transmits the print data to the three-dimensional object forming device 11. The print data may have creases set in the image processing device 12.

FIG. 4 is a diagram showing an example of a crease setting screen according to the first embodiment. Specifically, FIG. 4 shows an example of a software user interface for setting creases in print data displayed on the display device of the image processing device 12.

As shown in FIG. 4, in the image processing apparatus 12, the folding position P as a crease is set in the print data of the modeled object O. The folding position P is a position designated as a bending position in the modeled object O. The folding position P is set, for example, in a straight line crossing the modeled object O. The bending position P is not limited to this example.

The operator can change the position and orientation of the bending position P by using, for example, a cursor. In addition, the operator can set a plurality of bending positions P. The folding position P may not be set in the print data.

Further, the folding direction for each bending position P is set in the print data. The bending direction is the direction designated as the direction in which the modeled object O is bent at the bending position P. Specifically, whether it is a mountain fold or a valley fold is set for each bending position P. The operator can set a mountain fold or a valley fold for the bending position P, for example, by checking the radio button. The bending direction can also be expressed as a folding method (folding method).

The set bending position P and bending direction are included in the print data, for example. The image processing device 12 transmits print data including the bending position P and the bending direction to the three-dimensional object forming device 11. The folding position P and the folding direction may be created and saved as data different from the print data. In this case, the image processing device 12 transmits the data of the bending position P and the bending direction together with the print data to the three-dimensional object forming device 11.

An example of the process of forming the modeled object O by the image processing system 10 of the present embodiment will be described below. The image processing system 10 may form the modeled object O by a process different from the process described below.

FIG. 5 is a flowchart showing an example of the forming process of the modeled object O in the first embodiment. As shown in FIG. 5, first, the data receiving unit 41 acquires the print data (S11). Next, the discriminating unit 42 determines whether or not the modeled object O in the print data is formed by laminated printing (S12). That is, the discriminating unit 42 determines whether the modeled object O in the print data has a plurality of layers L or only one layer L.

When the modeled object O in the print data has only one layer L and is not formed by laminated printing (S12: No), the conversion unit 43 does not create the conversion data, and the recording control unit 44 is based on the print data. Single-layer printing is executed (S13), and the formation of the modeled object O is completed. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record one layer L forming the modeled object O.

On the other hand, in S12, when the modeled object O in the print data has a plurality of layers L and is formed by laminated printing (S12: Yes), the discriminating unit 42 is at the bent position P at the modeled object O in the print data. Is set or not (S14). That is, the determination unit 42 determines whether or not the print data includes information on the bending position P and the bending direction, or whether or not there is data on the bending position P and the bending direction corresponding to the print data. .. When the folding position P is set (S14: Yes), the conversion unit 43 executes a partial deletion process of the print data described below (S15).

FIG. 6 is a flowchart showing an example of the print data partial deletion process S15 according to the first embodiment. As shown in FIG. 6, in the print data partial deletion process S15, the conversion unit 43 first selects one unprocessed bending position P (S21).

In the following description, as shown in FIG. 2, it is assumed that four bending positions P are set in the modeled object O. Hereinafter, the four bending positions P may be individually referred to as bending positions P1, P2, P3, and P4.

The number of layers L at the folding position P1 is two. Further, at the bending position P1, the folding direction of the mountain fold is set. The number of layers L at the folding position P2 is three. Further, at the bending position P2, the folding direction of the valley fold is set. The number of layers L at the folding position P3 is three. Further, at the folding position P3, the folding direction of the mountain fold is set. The number of layers L at the folding position P4 is two. Further, at the bending position P4, the folding direction of the valley fold is set.

Returning to FIG. 6, the conversion unit 43 then acquires the number of layers L at the selected bending position P from the print data (S22). If the folding positions P1 and P4 are selected, the number of layers L is two. If the folding positions P2 and P3 are selected, the number of layers L is three.

Next, the conversion unit 43 determines whether or not the bending direction set at the selected bending position P is a mountain fold (S23). If the folding positions P1 and P3 are selected, the folding direction is a mountain fold. If the folding positions P2 and P4 are selected, the folding direction is valley fold.

When the folding direction is a mountain fold (S23: Yes), the conversion unit 43 reads out the mountain fold deletion width data 45A stored in the storage unit 45. Table 1 shows an example of the mountain fold deletion width data 45A in the first embodiment. The conversion unit 43 selects the deletion width W according to the number of layers L at the selected folding position P from the mountain fold deletion width data 45A (S24). The deletion width W may be calculated from a function, for example.

Next, the conversion unit 43 deletes the portion located on the selected folding position P and having the selected deletion width W from the print data (S26). Specifically, the conversion unit 43 sets a region having a deletion width W selected based on Table 1 in the horizontal direction orthogonal to the linear bending position P with the bending position P as the center. Further, the conversion unit 43 deletes a portion (a pixel in the raster data or a portion in the coordinates in the vector data) whose coordinates in the horizontal direction are located in the region from the print data. As a result, in the print data, a groove S extending along the bending position P and having a selected deletion width W is formed in the modeled object O.

On the other hand, when the folding direction is not a mountain fold but a valley fold in S23 (S23: No), the conversion unit 43 reads out the valley fold deletion width data 45B stored in the storage unit 45. Table 1 also shows an example of the valley fold deletion width data 45B in the first embodiment. The conversion unit 43 selects the deletion width W according to the number of layers L at the selected folding position P from the valley fold deletion width data 45B (S25). Then, the conversion unit 43 deletes the portion located on the selected folding position P and having the selected deletion width W from the print data (S26).

As shown in Table 1 and FIG. 2, the deletion width W in the case of valley fold is larger than the deletion width W in the case of mountain fold. That is, the conversion unit 43 determines the deletion width W of the portion located on the folding position P to be deleted from the print data based on the folding direction.

Further, as shown in Table 1 and FIG. 2, as the number of layers L increases, the deletion width W of the portion located on the bending position P to be deleted from the print data is set wider. That is, the conversion unit 43 determines the deletion width W of the portion located on the bending position P to be deleted from the print data based on the number of layers L. The deletion width is not limited to this example. For example, the deletion width W in the mountain fold deletion width data 45A may be constant.

Returning to FIG. 6, when the portion located on the bending position P selected in S26 is deleted, the conversion unit 43 determines whether or not there is an unprocessed bending position P (S27). When there is an unprocessed bending position P (S27: Yes), the conversion unit 43 returns to S21 and selects one unprocessed bending position P again. The conversion unit 43 repeats the above processes S21 to S27 until all the bending positions P are processed.

When there is no unprocessed bending position P in S27 (S27: No), the conversion unit 43 ends the print data partial deletion process S15 and returns to the flow of FIG. The conversion unit 43 converts the print data into conversion data in which a part of the print data is deleted by processing all the bending positions P. In other words, the conversion unit 43 creates the conversion data in which a part of the print data is deleted from the print data.

Returning to the flow of FIG. 5, the recording control unit 44 executes laminated printing based on the conversion data (S16), and completes the formation of the modeled object O. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record a plurality of layers L forming the modeled object O. As a result, the recording unit 21 forms the modeled object O based on the converted data.

FIG. 7 is a cross-sectional view schematically showing the folded model O in the first embodiment. The modeled object O formed based on the conversion data is provided with a groove S on the bent position P, unlike the modeled object O in the original print data. By providing the groove S, the modeled object O can be easily bent at the bending position P.

At the folding positions P1 and P3, the folding direction is set to mountain fold. Therefore, when the modeled object O is mountain-folded at the bent positions P1 and P3, a part of the modeled object O provided across the groove S is separated from each other. By setting the width of the groove S at the bending positions P1 and P3 to be narrow, the groove S is suppressed from being conspicuous.

At the folding positions P2 and P4, the folding direction is set to valley fold. Therefore, when the modeled object O is valley-folded at the bent positions P2 and P4, a part of the modeled object O provided across the groove S approaches each other. By setting the width of the groove S at the bending positions P2 and P4 to be wide, it is possible to prevent a part of the modeled objects O provided with the groove S from interfering with each other. Further, since the width of the groove S is wider as the number of layers L is larger, it is further suppressed that a part of the modeled objects O provided across the groove S interfere with each other.

Returning to FIG. 5, when the bending position P is not set in S14 (S14: No), the conversion unit 43 does not create the conversion data, and the recording control unit 44 executes laminated printing based on the print data (S16). ), Complete the formation of the model O. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record a plurality of layers L forming the modeled object O. As a result, the recording unit 21 forms the modeled object O based on the print data.

According to the image processing system 10 of the first embodiment described above, for example, the conversion unit 43 is placed on the bending position P designated as the bending position in the modeling object O from the print data of the modeling object O. Create conversion data with at least part of the location removed. The conversion unit 43 determines the deletion width W of the portion located on the folding position P to be deleted from the print data, based on the bending direction designated as the bending direction of the modeled object O at the folding position P. Since the deletion width W can be changed based on the bending direction, interference between a part of the modeled objects O at the time of valley folding is suppressed due to the narrow deletion width W. As a result, the modeled object O can be easily bent regardless of the bending direction. Further, it is suppressed that the deletion width W at the folding position P where the mountain is folded becomes wide.

The conversion unit 43 determines the deletion width W of the portion located on the bending position P to be deleted from the print data based on the number of the plurality of layers L. As a result, even when there are many layers L, interference between a part of the modeled object O at the time of valley folding is suppressed. Further, the deletion width W can be set to the minimum, and it is possible to prevent the deletion width W from becoming wide when the number of layers L is small.

(Second Embodiment)
Hereinafter, a three-dimensional object forming apparatus to which the present invention is applied, an image processing method, and a second embodiment of the program will be described. FIG. 8 is a cross-sectional view schematically showing the modeled object O in the second embodiment. As shown in FIG. 8, in the second embodiment, the deletion width of the portion located on the folding position P to be deleted from the print data is determined for each of the plurality of layers L.

The configuration of the image processing system 10 in the second embodiment is the same as that in the first embodiment. Further, the formation process of the modeled object O in the second embodiment is the same as that in the first embodiment except for the partial deletion process S15 of the print data. Therefore, the print data partial deletion process S15 of the second embodiment will be described below.

FIG. 9 is a flowchart showing an example of the print data partial deletion process S15 in the second embodiment. As shown in FIG. 9, in the partial deletion processing S15 of the print data in the second embodiment, the conversion unit 43 first selects one unprocessed bending position P (S121).

Next, the conversion unit 43 selects the print data of the lowest layer among the unprocessed layers L (S122). Specifically, the conversion unit 43 selects the print data of the layer L closest to the base material B among the unprocessed layers L in the print data.

Next, the conversion unit 43 determines whether or not the bending direction set at the selected bending position P is a mountain fold (S123). If the folding positions P1 and P3 are selected, the folding direction is a mountain fold. If the folding positions P2 and P4 are selected, the folding direction is valley fold.

When the folding direction is a mountain fold (S123: Yes), the conversion unit 43 reads out the mountain fold deletion width data 45A stored in the storage unit 45. Table 2 shows an example of the mountain fold deletion width data 45A in the second embodiment. The conversion unit 43 selects a deletion width according to the number of the selected layer L from the mountain fold deletion width data 45A (S124). The deletion width W may be calculated from a function, for example. The layer L is numbered in order from, for example, the layer L closest to the base material B.

Next, the conversion unit 43 deletes a portion of the print data layer L located on the selected bending position P and having the selected deletion width (S126). As a result, in the print data, a groove S extending along the bending position P and having a selected deletion width is formed in the layer L.

On the other hand, when the folding direction is not a mountain fold but a valley fold in S123 (S123: No), the conversion unit 43 reads the valley fold deletion width data 45B stored in the storage unit 45. Table 2 also shows an example of the valley fold deletion width data 45B in the second embodiment. The conversion unit 43 selects the deletion width according to the number of the selected layer L from the valley fold deletion width data 45B (S125). Then, the conversion unit 43 deletes a portion of the print data layer L that is located on the selected bending position P and has the selected deletion width (S126).

As shown in Table 2 and FIG. 8, the deletion width in the case of valley folds is larger than the deletion width in the case of mountain folds. That is, the conversion unit 43 determines the deletion width of the portion located on the folding position P to be deleted from the print data based on the folding direction.

Further, as shown in Table 2 and FIG. 8, the layer L farther from the base material B is set to have a wider deletion width of the portion located on the bending position P to be deleted from the print data. That is, the conversion unit 43 determines the deletion width of the portion located on the bending position P to be deleted from the print data for each of the plurality of layers L. The deletion width is not limited to this example. For example, in the mountain fold deletion width data 45A, the deletion width of the portion located on the folding position P to be deleted from the print data may be constant.

Returning to FIG. 9, when the portion located on the folding position P selected in S126 is deleted, the conversion unit 43 deletes a part of the print data located on the folding position P for all the layers L. Whether or not it is determined (S127). When there is an unprocessed layer L (S127: No), the conversion unit 43 returns to S122 and selects the print data of the lowest layer of the unprocessed layers L again. The conversion unit 43 repeats the above processes S122 to S127 until a part of the print data located on the bending position P is deleted for all the layers L.

On the other hand, when the deletion processing of all the layers L is completed in S127 (S127: Yes), the conversion unit 43 determines whether or not there is an unprocessed bending position P (S128). When there is an unprocessed bending position P (S128: Yes), the conversion unit 43 returns to S121 and selects one unprocessed bending position P again. The conversion unit 43 repeats the above processes S121 to S128 until all the bending positions P are processed.

When there is no unprocessed bending position P in S128 (S128: No), the conversion unit 43 ends the partial deletion process S15 of the print data and returns to the flow of FIG. The conversion unit 43 converts the print data into conversion data in which a part of the print data is deleted by processing all the bending positions P.

Returning to the flow of FIG. 5, the recording control unit 44 executes laminated printing based on the conversion data (S16), and completes the formation of the modeled object O. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record a plurality of layers L forming the modeled object O. As a result, the recording unit 21 forms the modeled object O based on the converted data.

FIG. 10 is a cross-sectional view schematically showing the folded model O in the second embodiment. At the folding positions P2 and P4, the folding direction is set to valley fold. Therefore, when the modeled object O is valley-folded at the bent positions P2 and P4, a part of the modeled object O provided across the groove S approaches each other. The width of the groove S of the second embodiment is set wider as the distance from the base material B is increased. As a result, it is possible to prevent a part of the modeled objects O provided with the groove S from interfering with each other.

According to the image processing system 10 of the second embodiment described above, for example, the conversion unit 43 deletes the portion of each of the plurality of layers L located on the bending position P to be deleted from the print data. Determine the width. For example, the closer the layer is to the base material B, the narrower the deletion width of the deleted portion. As a result, the deleted portion becomes less noticeable, and interference between parts of the modeled object O at the time of valley folding is suppressed. As a result, the modeled object O can be easily bent regardless of the bending direction.

(Third Embodiment)
Hereinafter, a three-dimensional object forming apparatus to which the present invention is applied, an image processing method, and a third embodiment of the program will be described. FIG. 11 is a cross-sectional view schematically showing a part of the modeled object O in the third embodiment.

The configuration of the image processing system 10 in the third embodiment is the same as that of the first embodiment or the second embodiment. Further, the forming process of the modeled object O in the third embodiment is the first embodiment or the second embodiment except for the process (S26 or S126) of deleting the portion located on the bent position P from the print data. It is the same as the form. Therefore, the processes S26 and S126 for deleting the portion located on the bent position P from the print data in the third embodiment will be described below. In FIG. 11, the solid line indicates the groove S formed in the first embodiment, and the alternate long and short dash line indicates the groove S formed in the second embodiment.

As shown in FIG. 11, the plurality of layers L of the modeled object O include a plurality of first layers L1 and a plurality of second layers L2. The first layer L1 is formed by additional droplets and is white or transparent. The first layer L1 is not limited to this example, and may have another color such as black or may be translucent. The second layer L2 is formed by ink droplets and has a different color from the first layer L1. The second layer L2 is provided, for example, on or near the surface of the modeled object O. The first layer L1 is provided inside the modeled object O. The first layer L1 and the second layer L2 are not limited to this example.

In the third embodiment, after the deletion width is determined in S24, S25, S124 or S125, the conversion unit 43 is located on the bending position P from the print data or the layer L of the print data and is selected. The portion showing the plurality of widths of the first layer L1 (first layer L1 in the print data) is deleted. That is, the conversion unit 43 of the third embodiment partially deletes the portion located on the bending position P from the print data. As a result, the conversion unit 43 creates conversion data in which the plurality of first layers L1 located on the bending position P are deleted.

The second layer L2 remains on the bending position P of the converted data. As a result, the second layer L2 covers the base material B. In FIG. 11, as an example, the space between the second layer L2 and the base material B on the bending position P is clogged. However, there may be a gap between the second layer L2 and the base material B on the bent position P.

According to the image processing system 10 of the third embodiment described above, for example, the plurality of layers L have a plurality of white or transparent first layers L1 and different colors from the first layer L1. It has a plurality of second layers L2. The conversion unit 43 creates conversion data in which the portions indicating the plurality of first layers L1 located on the bending position P are deleted from the print data. As a result, the colored second layer L2 remains even at the bent position P, so that the deleted portion becomes less noticeable. Further, since the first layer L1 is deleted, a part of the modeled object O on the bent position P becomes thin, so that the modeled object O can be easily bent at the bent position P.

(Fourth Embodiment)
Hereinafter, a fourth embodiment of the three-dimensional object forming apparatus, the image processing method, and the program to which the present invention is applied will be described. FIG. 12 is a block diagram functionally showing the image processing system 10 according to the fourth embodiment.

In the fourth embodiment, the image processing device 12 includes a data receiving unit 61, a discriminating unit 62, a conversion unit 63, an output unit 64, and a storage unit 65. A part or all of the data receiving unit 61, the discriminating unit 62, the converting unit 63, and the output unit 64 may be realized by, for example, causing a processing device such as a CPU to execute the program, that is, by software. However, it may be realized by hardware such as an IC, or it may be realized by using software and hardware together.

The data receiving unit 61 receives the print data of the modeled object O. The data receiving unit 61 acquires the print data from, for example, a storage unit 65 in which the print data is stored in advance. The data receiving unit 61 may acquire the print data from an information recording medium such as a CD or a DVD in which the print data is stored.

When a crease is set in the modeled object O, the determination unit 62 and the conversion unit 63 create conversion data from the print data. The output unit 64 outputs the print data or the conversion data to the three-dimensional object forming apparatus 11.

The control unit 24 of the three-dimensional object forming device 11 includes a data receiving unit 41 and a recording control unit 44. The data receiving unit 41 acquires print data or converted data from the image processing device 12 via the communication unit. The recording control unit 44 controls the recording unit 21 and the driving unit 23 based on the received print data or conversion data to form the modeled object O.

FIG. 13 is a flowchart showing an example of image processing of the print data of the modeled object O in the fourth embodiment. As shown in FIG. 13, first, the data receiving unit 61 acquires the print data (S211). Next, the discriminating unit 62 determines whether or not the modeled object O in the print data is formed by laminated printing (S212).

When the modeled object O in the print data has only one layer L and is not formed by laminated printing (S212: No), the conversion unit 63 does not create the conversion data, and the output unit 64 prints the print data as a three-dimensional object. It is output to the forming apparatus 11 (S213), and the image processing is completed. The three-dimensional object forming device 11 forms the modeled object O based on the print data.

On the other hand, in S212, when the modeled object O in the print data has a plurality of layers L and is formed by laminated printing (S212: Yes), the discriminating unit 62 is at the bent position P at the modeled object O in the print data. Is set or not (S214). When the folding position P is set (S214: Yes), the conversion unit 63 performs a partial deletion process of the print data as in the first embodiment, the second embodiment, or the third embodiment. Execute (S215).

The discrimination unit 62, the conversion unit 63, and the storage unit 65 of the image processing device 12 are the discrimination unit 42, the conversion unit 43, and the storage unit 45 of the first embodiment, the second embodiment, or the third embodiment. Similarly, by the processing of S21 to 27 of FIG. 6 or S121 to 128 of FIG. 9, the partial deletion processing S215 of the print data is performed, and the conversion data is created from the print data. The operations of the determination unit 62, the conversion unit 63, and the storage unit 65 are the operation of the determination unit 42, the conversion unit 43, and the storage unit 45 in the description of the first embodiment, the second embodiment, or the third embodiment. It is the same.

Returning to the flow of FIG. 13, the output unit 64 outputs the conversion data to the three-dimensional object forming device 11 (S213), and completes the image processing. The three-dimensional object forming device 11 forms the modeled object O based on the conversion data.

When the bending position P is not set in S214 (S214: No), the conversion unit 63 does not create the conversion data, the output unit 64 outputs the print data to the three-dimensional object forming device 11 (S213), and the image Complete the process. The three-dimensional object forming device 11 forms the modeled object O based on the print data.

As described above, in the first to third embodiments, the three-dimensional object forming apparatus 11 creates the conversion data from the print data and forms the modeled object O based on the conversion data. On the other hand, in the fourth embodiment, the image processing device 12 creates conversion data from the print data, and the three-dimensional object forming device 11 forms the modeled object O based on the conversion data. As described above, in the image processing system 10, the process of creating the conversion data from the print data may be performed by the three-dimensional object forming device 11 or the image processing device 12.

(Hardware configuration)
The hardware configurations of the image processing device 12 and the control unit 24 in each embodiment will be described below. FIG. 14 is a block diagram showing an example of a schematic configuration of the image processing device 12 and the control unit 24 in each embodiment.

The image processing device 12 includes a CPU 101, a ROM 102, a RAM 103, an auxiliary storage device 104, a communication unit 105, and an interface (I / F) 106 that are electrically connected to each other by a bus 100. For example, a display device or an input device is connected to the I / F 106.

The CPU 101 is a central control unit that controls the entire image processing device 12 according to a program stored in the ROM 102 or the auxiliary storage device 104. The CPU 101 controls, for example, data communication, reading of an application program by accessing a memory, reading / writing of various data, data / command input, display, and the like. Further, the CPU 101 sends print data or conversion data to the three-dimensional object forming apparatus 11 via the communication unit 105.

The RAM 103 includes a work memory for storing a designated program, an input instruction, input data, a processing result, and the like. The auxiliary storage device 104 stores various programs and data such as an OS program that can be executed by the CPU 101 and a printer driver corresponding to the three-dimensional object forming device 11.

The control unit 24 includes a CPU 201, a ROM 202, a RAM 203, an auxiliary storage device 204, a communication unit 205, and an I / F 206 that are electrically connected to each other by a bus 200. The communication unit 105 of the image processing device 12 and the communication unit 205 of the control unit 24 are connected to each other so as to be able to communicate with each other directly or via a network by wire or wirelessly.

The CPU 201 is a central control unit that controls the entire three-dimensional object forming device 11 according to a program stored in the ROM 202 or the auxiliary storage device 204. The CPU 201 controls, for example, data communication, reading of an application program by accessing a memory, reading / writing of various data, data / command input, display, and the like. Further, the CPU 201 controls the recording unit 21 and the driving unit 23 based on the print data or the conversion data to form the modeled object O.

The RAM 203 includes a work memory for storing a designated program, an input instruction, input data, a processing result, and the like. The auxiliary storage device 204 stores an OS program, various programs, and data that can be executed by the CPU 201.

The program executed by the image processing apparatus 12 of each of the above embodiments is a file in an installable format or an executable format, such as a CD-ROM, a flexible disk (FD), a CD-R, or a DVD (Digital Versaille Disk). It is recorded and provided on a computer-readable recording medium.

Further, the program executed by the image processing device 12 of each embodiment may be stored on a computer connected to a network such as the Internet and provided by downloading via the network. Further, the program executed by the image processing device 12 of the present embodiment may be configured to be provided or distributed via a network such as the Internet.

Further, the program of each embodiment may be configured to be provided by incorporating it into a ROM or the like in advance.

The program executed by the image processor 12 of each embodiment has a module configuration including the above-mentioned units (data receiving unit 61, discrimination unit 62, conversion unit 63, output unit 64, and storage unit 65). As actual hardware, when a CPU (processor) reads a program from the storage medium and executes it, each of the above units is loaded onto the main storage device, and the data receiving unit 61, the discriminating unit 62, the conversion unit 63, and the output unit 64 are loaded. , And the storage unit 65 is designed to be generated on the main storage device.

Further, the program executed by the three-dimensional object forming apparatus 11 of each of the above embodiments is provided by being incorporated in a ROM or the like in advance.

The program executed by the three-dimensional object forming apparatus 11 of each embodiment is recorded on a computer-readable recording medium such as a CD-ROM, FD, CD-R, or DVD in an installable format or an executable format file. It may be configured to provide.

Further, the program executed by the three-dimensional object forming apparatus 11 of each embodiment may be stored on a computer connected to a network such as the Internet and provided by downloading via the network. Further, the program executed by the three-dimensional object forming apparatus 11 of the present embodiment may be provided or distributed via a network such as the Internet.

The program executed by the three-dimensional object forming device 11 of each embodiment has a modular configuration including the above-mentioned units (data receiving unit 41, discrimination unit 42, conversion unit 43, recording control unit 44, and storage unit 45). As the actual hardware, when the CPU (processor) reads the program from the ROM and executes it, each of the above parts is loaded on the main memory, and the data receiving unit 41, the discriminating unit 42, the conversion unit 43, and the recording control A unit 44 and a storage unit 45 are generated on the main storage device.

In the above-mentioned plurality of embodiments, the three-dimensional object forming apparatus 11 forms a three-dimensional object by a three-dimensional additive manufacturing method by a stereolithography method. However, the three-dimensional object forming apparatus 11 may form a three-dimensional object by a material extrusion lamination method (FDM), powder sintering lamination modeling (SLS), or various other three-dimensional lamination modeling methods.

In the stereolithography method, a liquid photocurable resin is sprayed by an inkjet to form a layer, and the layer of the photocurable resin is cured by light irradiated according to a cross-sectional shape to form a three-dimensional object. In the material extrusion lamination method, a layer is formed by supplying a resin melted by heat from a nozzle, and the resin layers are laminated according to a cross-sectional shape to create a three-dimensional object. In powder sintering layered manufacturing, a layer made of powder is formed, the surface of the layer is irradiated with laser light, and the powder is sintered by the laser light according to the cross-sectional shape to create a three-dimensional object.

(Fifth Embodiment)
Hereinafter, a three-dimensional object forming apparatus to which the present invention is applied, an image processing method, and a fifth embodiment of the program will be described.

In the conventional method for forming a three-dimensional object, there is a problem that a separate measure is required when image quality deterioration occurs due to banding. Banding refers to an abnormal image in which band-shaped stripes due to shading occur in the formed image due to various causes such as a deviation in the amount of line feed and the amount of media conveyed, or a variation in ejection efficiency of the recording unit 21. The boundary of the stripes is visually recognized as white streaks or black streaks, which significantly impairs the quality of the image.

Here, FIG. 15 is a diagram showing an example of banding occurrence in a conventional three-dimensional model. As shown in FIG. 15, when a plurality of layers are laminated when forming a three-dimensional model, the banding is added to form a concave line for white streaks and a convex line for black streaks. Further, as described in the first to third embodiments, when the bent portion is arbitrarily set, there is a possibility that the image quality may be deteriorated when banding occurs.

Here, FIG. 16 is a diagram showing an example of banding occurrence in a conventional three-dimensional model in which a bent portion is arbitrarily set. FIG. 16 (a) is a view of a three-dimensional model having an arbitrarily set bent portion as viewed from the printed surface side, and FIG. 16 (b) is a view of a three-dimensional model having an arbitrarily set bent portion as viewed from the side surface in the stacking direction. It is a figure. The three-dimensional model shown in FIG. 16 is a model that can be bent into five equal parts at the bending position P.

FIG. 16A shows the relationship between the image data deletion position and the banding occurrence position. As shown in FIG. 16A, the image data deletion position is a line of Y = 9 mm, 18 mm, 27 mm, 36 mm from the image start position, which is different from the banding occurrence position. Therefore, as shown in FIG. 16B, there is a problem that an abnormal line of concave or convex remains in the modeled object while banding remains.

In the conventional image processing method, in order to solve the above-mentioned problems, there is a technique of adjusting the line feed amount and the media transport amount in μm units, but high machine accuracy is required and printing evaluation is performed multiple times for visual adjustment. There is a demerit that it is required.

Further, even if the line feed amount and the media transport amount are accurate, if the ejection efficiency of the recording unit 21 varies, a band-shaped abnormal image is similarly generated. In order to solve this, measures such as increasing the number of passes to disperse the variation in nozzle injection characteristics and designing a mask are taken, but productivity is reduced and a complicated mask design is required. There are disadvantages such as.

Here, FIG. 17 is a block diagram functionally showing the image processing system 10 according to the fifth embodiment. As shown in FIG. 17, the image processing system 10 includes a calculation unit 50 in addition to the configuration described in FIG.

When the print data is input, the determination unit 42 determines whether or not the printing is laminated printing, whether or not there are creases, and whether or not banding is avoided.

When avoiding banding, the calculation unit 50 predicts the banding occurrence position. Then, the calculation unit 50 sends the predicted banding position as a bending position to the conversion unit 43. For example, the calculation unit 50 can reduce the user load by automatically calculating the banding position from the print mode. An example of banding occurrence position prediction calculation in the calculation unit 50 is shown below.
Banding occurrence position = (head length of recording unit 21 / number of passes) × n (n is an integer of 1 or more)

When a crease is set in the modeled object O, the conversion unit 43 creates conversion data in which a part is deleted from the print data.

The recording control unit 44 controls the recording unit 21 and the driving unit 23 based on the print data or the conversion data to form the modeled object O.

Next, the flow of the forming process of the modeled object O in the fifth embodiment will be described.

FIG. 18 is a flowchart showing the flow of the forming process of the modeled object O in the fifth embodiment. As shown in FIG. 18, first, the data receiving unit 41 acquires print data (S11). Next, the discriminating unit 42 determines whether or not the modeled object O in the print data is formed by laminated printing (S12). That is, the discriminating unit 42 determines whether the modeled object O in the print data has a plurality of layers L or only one layer L.

When the modeled object O in the print data has only one layer L and is not formed by laminated printing (S12: No), the conversion unit 43 does not create the conversion data, and the recording control unit 44 is based on the print data. Single-layer printing is executed (S13), and the formation of the modeled object O is completed. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record one layer L forming the modeled object O.

On the other hand, in S12, when the modeled object O in the print data has a plurality of layers L and is formed by laminated printing (S12: Yes), the discriminating unit 42 is at the bent position P at the modeled object O in the print data. Is set or not (S14). That is, the determination unit 42 determines whether or not the print data includes information on the bending position P and the bending direction, or whether or not there is data on the bending position P and the bending direction corresponding to the print data. ..

When the bending position P is not set in S14 (S14: No), the conversion unit 43 does not create the conversion data, the recording control unit 44 executes laminated printing based on the print data (S16), and the modeled object O Complete the formation of. That is, the recording control unit 44 controls the recording unit 21 and the driving unit 23 to record a plurality of layers L forming the modeled object O. As a result, the recording unit 21 forms the modeled object O based on the print data.

On the other hand, when the bending position P is set (S14: Yes), the discriminating unit 42 determines whether to avoid banding (S31). In principle, the banding depends on the line feed position unless a complicated striking order mask is used, and the banding occurrence position can be easily estimated from the width of the recording unit 21 and the number of passes. That is, the determination unit 42 determines whether or not there is a banding occurrence position based on the print data.

When banding is not avoided (S31: No), the conversion unit 43 executes the above-described partial deletion process of the print data at the bending position (S15). After that, the recording control unit 44 executes laminated printing based on the print data (S16), and completes the formation of the modeled object O.

On the other hand, when avoiding banding (S31: Yes), the calculation unit 50 predicts the banding occurrence position and sends the predicted banding position as a bending position to the conversion unit 43 (S32).

The conversion unit 43 executes a partial deletion process of the print data at the folding position described above (S15). After that, the recording control unit 44 executes laminated printing based on the print data (S16), and completes the formation of the modeled object O.

Here, FIG. 19 is a diagram showing an example of forming the modeled object O in the fifth embodiment. FIG. 19A is a view of the modeled object O viewed from above, and FIG. 19B is a view of modeled object O viewed from the side surface. The modeled object O shown in FIG. 19 is a modeled object that can be bent into five equal parts at the bending position P.

As shown in FIG. 19A, in the present embodiment, the image data deletion position is intentionally overlapped with the banding occurrence position. That is, as shown in FIG. 19A, the image data deletion position is set at positions Y = 10 mm, 20 mm, 30 mm, and 40 mm from the image start position. By doing so, it is possible to eliminate the abnormal lines of concave or convex formed in the three-dimensional structure without requiring high-precision adjustment of the device.

As described above, according to the present embodiment, it is possible to avoid deterioration of image quality due to banding by superimposing the print data deletion position on the banding position.

In order to eliminate banding, in addition to a method of adjusting the device with high precision, a method of increasing the number of passes to disperse the variation in nozzle injection characteristics can be used, but the method of the present embodiment is the smallest. Since banding can be taken even with 1 pass, it is also effective in improving productivity.

Further, the calculation unit 50 may perform a test print of the image once, and then the user may specify an arbitrary position as the banding position.

Further, the calculation unit 50 does not have to be a line horizontal to the main scanning direction when accepting an arbitrary designation by the user. For example, when an abnormal image perpendicular to the main scanning direction is generated for some reason, the calculation unit 50 accepts the abnormal image line generation position specified by the user, and the conversion unit 43 deletes the print data at the bending position. If this is done, the effect of avoiding deterioration of image quality can be obtained as in the case of banding countermeasures.

The above-described embodiment of the present invention does not limit the scope of the invention, but is merely an example included in the scope of the invention. An embodiment of the present invention is modified, omitted, and at least a part of a specific use, structure, shape, action, and effect with respect to the above-described embodiment without departing from the gist of the invention. It may be an addition.

10 Image processing system 11 Three-dimensional object forming device 12 Image processing device 21 Recording unit 41 Data receiving unit 43 Conversion unit 50 Calculation unit 61 Data receiving unit 63 Conversion unit L layer L1 First layer L2 Second layer O Modeled object P, P1, P2, P3, P4 Bending position W Delete width

Japanese Unexamined Patent Publication No. 2017-095676

Claims (8)

A data receiving unit that receives 3D image data of a three-dimensional object containing multiple layers,
A data creation unit that creates three-dimensional formation data by deleting at least a part of a portion located on a bending position designated as a bending position in the three-dimensional object from the three-dimensional image data.
A forming portion that forms the three-dimensional object based on the three-dimensional formation data,
With
The data creation unit determines the width of the portion located on the folding position to be deleted from the three-dimensional image data based on the bending direction designated as the bending direction of the three-dimensional object at the folding position. ,
A three-dimensional object forming device characterized by this. The data creation unit determines the width of the portion located on the bent position to be deleted from the three-dimensional image data based on the number of the plurality of layers.
The three-dimensional object forming apparatus according to claim 1. The data creation unit determines the width of a portion of each of the plurality of layers located on the bent position to be deleted from the three-dimensional image data.
The three-dimensional object forming apparatus according to claim 1. The plurality of layers include a first layer and a second layer having a color different from that of the first layer.
The data creation unit creates the three-dimensional formation data in which the portion indicating the first layer located on the bent position is deleted from the three-dimensional image data.
The three-dimensional object forming apparatus according to any one of claims 1 to 3, wherein the three-dimensional object forming apparatus is characterized in that. The data creation unit superimposes the bending position deleted from the three-dimensional image data on the banding occurrence position where banding is considered to occur.
The three-dimensional object forming apparatus according to any one of claims 1 to 4, wherein the three-dimensional object forming apparatus is characterized in that. It also has a calculation unit that predicts the position where the front banding occurs.
The three-dimensional object forming apparatus according to claim 5. An image processing method executed by a computer
A step of determining the deletion width based on the bending direction specified as the bending direction of the three-dimensional object at the bending position designated as the bending position of the three-dimensional object including a plurality of layers.
A step of creating three-dimensional formation data in which a portion located on the bent position and having the deletion width is at least partially deleted from the three-dimensional image data of the three-dimensional object.
An image processing method characterized by including. At the bending position designated as the bending position of the three-dimensional object including a plurality of layers, the step of determining the deletion width based on the bending direction designated as the bending direction of the three-dimensional object, and
A step of creating three-dimensional formation data in which a portion located on the bent position and having the deletion width is at least partially deleted from the three-dimensional image data of the three-dimensional object.
A program that lets your computer run.

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