WO2016063090A1

WO2016063090A1 - Customisable dolls

Info

Publication number: WO2016063090A1
Application number: PCT/GB2015/053210
Authority: WO
Inventors: Andrew Paul RATCLIFFE
Original assignee: Ratcliffe Andrew Paul
Priority date: 2014-10-24
Filing date: 2015-10-26
Publication date: 2016-04-28
Also published as: GB201419000D0; GB2531609A; EP3209400A1

Abstract

A method of producing a plurality of doll components which, when assembled, form a doll, comprises the steps of:. processing an image containing one or more regions of a target tone;. providing a template comprising a plurality of doll parts which, when assembled, form a doll; and. selectively printing at least one of said doll parts of said template with one or more tones matching the one or more regions of a target tone.

Description

Customisab e Dolls

Field of the Invention

The invention relates to the production of dolls. It is particularly concerned with methods for the rapid production of dolls from a single piece of substrate material composition, whereby colours, tones and attributes from an image are processed and matched with a bank of predefined colours for printing onto components of the doll.

Background to the Invention

The closest prior art known to the applicant are toy dolls which comprise a number of components differing in material, the components being manufactured separately from one another and subsequently being assembled by gluing, sewing or by another attachment means. For example, many types of doll comprise limbs and a head comprising a plastics or ceramics material. The torso of the doll comprises cotton or a similar material which is prepared and cut separately from the production of the plastic head and limbs. As each of these components is produced through a separate manufacturing process, the production and assembling of the doll is complex and time consuming, and requires the use of a plurality of machines, each of which must be maintained and repaired. In another example of the prior art, rag dolls are produced from a number of material components which are cut from pre-coloured materials. The components of the body of the doll are coloured separately from the clothing or accessories of the doll, thereby limiting the speed with which the doll can be produced and assembled.

The present invention seeks to provide a method of producing a doll which simplifies and accelerates the process by which a doll is produced whilst allowing a more accurate production of the components of the doll. Summary of the Invention

In a first broad independent aspect, the invention provides a method of producing a plurality of doll components which, when assembled, forms a doll, comprising the steps of:

• processing an image containing one or more regions of a target tone;

· providing a template comprising a plurality of doll parts which, when assembled, form a doll; and

• selectively printing at least one of said doll parts of said template with one or more colours or tones matching the one or more regions of a target tone. This is particularly advantageous because it provides a simplified and accelerated method of producing a doll whereby all of the components of the doll are produced from a single material. This method also provides more accurate production of the doll components, which are produced with one or more printed tones from a processed image, allowing the skin tone or other chosen tones to be printed such that the assembled and completed doll can be a closer likeness of, for example, a person.

Preferably, the method comprises the further steps of identifying specific features, such as the eyes, mouth and nose of a target person in a processed image and providing specific sections on said template for said specific features. This step improves the accuracy with which a doll is produced such that it can more accurately represent a target person in an image without impairing the overall speed with which the doll is formed.

Preferably, the method comprises the further step of transferring the printed image of the template to a substrate. Transferring the printed image of the template to a substrate allows the accurately processed image to be conveyed on a fabric, plastics, ceramic, metallic_or similar material without impairing the quality of the representation or speed of the process. Preferably, the step of transferring the printed image to said substrate comprises placing the substrate in contact with the template and applying heat and/or pressure until the image printed on the template is fixed to the substrate. Alternative means of affecting this transfer may in some embodiments comprise a vacuum and heat combination, a chemical reaction, such as a photo-polymeric reaction, the use of UV or other radiation. This step ensures that the printed tones are effectively and accurately transferred to the substrate from the template. This is especially advantageous where the substrate is a fabric, and the heat and pressure applied to the substrate in contact with the template effectively fixes the printed tones to the fibres of the substrate. Preferably, the substrate comprises a plurality of doll parts which correspond to the plurality of doll parts of the template. This is particularly advantageous because it improves the speed and accuracy with which the plurality of doll parts can be cut from the substrate. It also provides guidelines to which each of the doll parts can be attached to one another to form the completed doll, further increasing the speed of the process.

Preferably, the method comprises the further step of cutting said plurality of doll parts out of said substrate. Cutting the plurality of doll parts out of the substrate allows the doll parts to be rapidly and accurately assembled into a complete doll. Preferably, the printed template is a single, 2-dimensional sheet comprising each of the plurality of doll parts. Providing a 2-dimensional printed template improves the speed with which each doll can be produced, as many sheets can be printed and subsequently stored or transported with ease. Preferably, the method comprises the further step of providing a user interface which allows a user to select one or more modifications which, when selected, modify the size and/or shape of at least one of the plurality of doll parts of said template. The user interface improves the accuracy of the completed doll compared with the processed image and/or the user's intended result, as individual components of the doll can be adjusted. Preferably, the method comprises the further step of using said user interface to adjust the tone matching the target tone. This step further improves the accuracy of the completed doll. It also allows a user to adjust the tones of the doll parts to provide different effects, such as a comic effect by, for example, increasing the 'red' tone of the cheek regions of the doll to convey an intoxicated effect.

Preferably, the method comprises the further step of selecting one or more features, such as facial features or accessories, from a library of predetermined features for printing on one or more of the plurality of doll parts of the template. A library of predetermined features including also birthmarks, scars and tattoos allows a user to customise the appearance of the doll.

Preferably, the method comprises the further step of printing an identity mark, such as a barcode, a message, a date of birth, a name or a greeting, onto a region of the template. Printing an identity mark onto a region of the template allows information to be displayed and stored with regard to each doll. It further simplifies the process of producing a doll as application of the identity mark does not require an additional manufacturing process with extra machinery. This step also allows an identity mark to be accurately positioned on a doll in an area of least inconvenience, which may vary between dolls.

Preferably, the method comprises the further step of shaping one or more of the plurality of doll parts of the printed template and/or substrate into a 3-dimensional doll. This step improves the formation of the completed 3-dimensional doll as shapes can be individually or collectively shaped.

Preferably, the method comprises the further steps of: providing a film, the film comprising a material which retains its form in ambient conditions and which becomes pliable under the application of heat and/or pressure and/or a chemical reaction; adhering said film to a non-printed surface of the doll part; and applying heat and/or pressure and/or a chemical reaction to the doll part and adhered film to shape them. These steps allow a doll part to be shaped into a 3-dimensional form so that the overall shape of the assembled doll is more realistic. These steps also allow the further customisation of a doll. The use of a film which is pliable under application of heat and/or pressure and/or a chemical reaction, and which retains its form in ambient conditions allows the doll part to be shaped in the design and manufacturing process whilst minimising or avoiding the risk that the doll part will lose its shape in use. Preferably, the method comprises the further step of adhering the film to a non-printed surface of one or more doll parts of the substrate. Adhering the film to doll parts of the substrate allows the substrate, once printed on, to be shaped. Adhering of the film to the substrate can be done before or after printing. Preferably, the film comprises a memory polymer

Preferably, the method comprises the step of providing one or more shaping tool and wherein said pressure is applied to opposed surfaces of the doll parts and adhered film via said shaping tools. Providing a number of shaping tools, between which the film and substrate of the doll parts are subject to pressure, allows the film and substrate to conform to the shape of the tools. This allows tools which have a specific shape of a doll part, such as the face of a doll, to be created.

Preferably, the method comprises the step of placing at least a region of a doll part in a vacuum to shape said doll part.

Preferably, the film is pliable at a temperature in the range of 80 to 150 degrees Celsius. This is preferable so that the film does not become pliable during normal use, e.g. on a hot day. A maximum temperature of 150 degrees Celsius minimises the risk that the film or substrate onto which the film is adhered is damaged at is it shaped. The substrate is likely to scorch at a temperature above 150 degrees Celsius.

Preferably, the method comprises the step of providing a user interface which allows a user to select one or more modifications which, when selected, modify the size and/or shape of said shaping tools. Providing user interface offers an operator more design freedom over the shape of the doll. This results in a more accurate and realistic finished product which more closely resembles the subject of the processed image. In a second broad independent aspect, the invention provides a system of manufacturing and providing a doll or component part thereof comprising:

• an image processor configured to process an image having one or more regions of a target tone;

• a template configured to outline a plurality of doll parts which, when assembled, form a doll; and

• a print head configured to print the surface of the template with one or more tones matching the one or more regions of a target tone, wherein the print head is configured to selectively print at least one of said doll parts.

This system is particularly advantageous because it provides a system for the simplified and accelerated production of a doll, whereby all of the components of the doll are contained on a single material. This system also provides more accurate production of the doll components, which are produced with one or more printed tones from an image processed by the image processor, allowing the skin tone or other chosen tones to be printed on the substrate such that the assembled and completed doll can be a precise representation of, for example, a person.

Preferably, the system further comprises a transfer module configured to transfer the one or more matched tones printed on the template to a substrate. The transfer module allows the processed image to be accurately transferred onto a substrate. This is particularly advantageous where the substrate is a fabric and the printed tones which are printed on the template can be accurately transferred to the fabric.

Preferably, the system further comprises a cutting unit configured to cut out each of said doll parts from said substrate. The cutting unit allows the plurality of doll parts to be cut out of the substrate rapidly and accurately such that the quality of the doll is improved and speed of the production of the doll is not hindered.

Preferably, the system further comprises a user interface configured to allow a user to modify the size and/or shape of at least one of the plurality of doll parts of said template. The user interface improves the accuracy of the completed doll compared with the processed image and/or the user's intended result, as individual components of the doll can be adjusted.

Preferably, said user interface is configured for the adjustment of the one or more matched tones. This configuration further improves the accuracy of the completed doll. It also allows a user to adjust the tones of the doll parts to provide different effects, such as a comic effect by, for example, increasing the 'red' tone of the cheek regions of the doll to convey an intoxicated effect. Preferably, the printer is a 3-dimensional printer. A 3-dimensional printer allows for the production of a 3-dimensional doll or component parts thereof. Tools required to shape the doll parts may also be printed by the 3-dimensional printer.JTie components of the doll may also be coloured and structured either simultaneously or in a staggered process. This further improves the speed and accuracy with which the doll is created as a fewer number of components may be required, and they may be at least partly assembled during printing. A full doll could also be printed which does not require assembly. A 3-dimensional printer also improves the reliability and reproducibility of the doll, which is especially advantageous where the doll is mass produced. Preferably, the image processor comprises a library of predetermined features from which features, such as facial features or accessories, are printed onto a region of the template. A library of predetermined features allows a user to customise the appearance of the doll.

Preferably, the printer is configured to print an identity mark, such as a barcode, onto a region of the template. The printer being configured to print an identity mark onto a region of the template allows information to be displayed and stored with regard to each doll. It further simplifies the process of producing a doll as application of the identity mark does not require an additional manufacturing process with extra machinery. This configuration also allows an identity mark to be accurately positioned on a doll in an area of least inconvenience, which may vary between dolls.

Preferably, the system further comprises a shaping unit for shaping one or more of the plurality of doll parts of the printed template and/or substrate into a 3-dimensional doll. The shaping unit improves the formation of the completed 3-dimensional doll as shapes can be individually or collectively shaped.

Preferably, the system further comprises a film, the film comprising a material which retains its form in ambient conditions and which becomes pliable under the application of heat and/or pressure and/or a chemical reaction; wherein the film is adhered to a non- printed surface of one or more doll parts and said shaping unit comprises a number of tools for applying heat and/or pressure and/or a chemical reaction to said film and doll parts. This system allows a doll part to be shaped into a 3-dimensional form so that the overall shape of the assembled doll is more realistic. This system also allows the further customisation of a doll. For instance, the face of the doll can be customised to more accurately represent that of a person commissioning the doll's creation. The use of a film which is pliable under application of heat and/or pressure and/or a chemical reaction, and which retains its form in ambient conditions allows the doll part to be shaped in the design and manufacturing process whilst minimising or avoiding the risk that the doll part will lose its shape in use. Solvents and chemical compounds may be used to shape the doll parts.

Preferably, said shaping unit comprises a heating element. Providing a heating element avoids the need for a separate heating element to be provided.

Preferably, said heating element is embedded in at least one of said tools. Embedding the heating element in at least one of said tools allows the heat to be effectively transferred from the at least one tool to the film and substrate 'sandwich'. Embedding the heating element also improves the safety of the system because it does not need to be carried or operated separately by an operator.

Preferably, the system further comprises a user interface which allows a user to select one or more modifications which, when selected, modifies the size and/or shape of said shaping unit. Providing user interface offers an operator more design freedom over the shape of the doll. This results in a more accurate and realistic finished product which more closely resembles the subject of the processed image. In a third broad independent aspect, the invention provides a method of producing a printed fabric which subsequently forms a piece of clothing, comprising the steps of:

• processing an image containing one or more regions of a target tone;

• providing a template comprising a fabric; and

• selectively printing at least a portion of said template with one or more colours or tones matching the one or more regions of a target tone

This is particularly advantageous because it provides a simplified and accelerated method of producing a piece of clothing whereby all of the components of the clothing are contained on a single substrate material which is printed with matched tones from an uploaded image.

In a further broad independent aspect, the invention provides a method of producing a plurality of components of an object which, when assembled, forms the complete object, comprising the steps of:

• processing an image containing one or more regions of a target tone;

• providing a template comprising a plurality of parts of an object which, when assembled, form the complete object; and

• selectively printing at least one of said object parts of said template with one or more tones matching the one or more regions of a target tone.

This is particularly advantageous because it provides a simplified and accelerated method of producing an object whereby all of the components of the object are contained on a single substrate material. This method also provides more accurate production of the components of an object, which are produced with one or more printed tones from a processed image.

In a subsidiary aspect, the method comprises the further steps of: providing a film, the film comprising a material which retains its form in ambient conditions and which becomes pliable under the application of heat and/or pressure and/or a chemical reaction; adhering said film to a non-printed surface of the object; and applying heat and/or pressure and/or a chemical reaction to the object and adhered film to shape them.

This configuration allows, for instance, an otherwise laminar object to be produced which comprises one or more protruding or hollowed regions.

Brief Description of the Drawings

Figure 1 shows a block diagram of the system of the invention.

Figure 2 shows a block diagram having the preferred additional components of a transfer module, a cutting unit and user interface.

Figure 3 shows a block diagram illustrating the image processing of an uploaded image.

Figure 4 shows a template of a preferred embodiment of the method and system of the invention.

Figure 5 shows a block diagram having the preferred components of a pressure and/or thermo-sensitive film and a shaping unit/tools.

Detailed Description of the Embodiments

The current invention provides a method and system of producing a plurality of doll components, which, when assembled, forms a doll. A block diagram illustrating the method and system of the current invention is shown in Figure 1.

In the embodiment of Figure 1, the method comprises the following general steps of processing an image containing one or more regions of a target tone; providing a template comprising a plurality of doll parts which, when assembled, form a doll; and selectively printing at least one of the doll parts of the template with one or more tones matching the one or more regions of a target tone, such that a whole doll is printed to provide a simplified and accelerated doll production process. In use, an image processor is provided onto which a user uploads an image from which they require at least one region of a target tone to be processed. The image may be provided by uploading it from a portable storage device, such as a USB stick or memory card, onto a computer comprising image processing software. Alternatively, the image may be scanned to the computer's local storage through a scanner, or it may be provided via email or another remote or wireless means. The image can also be provided in electronic form via the internet. If the image is not in an electronic form, it is converted to an electronic form for image processing. Once the image has been provided, the processor processes the image to identify one or more regions of a target tone. This may include the skin tone of the face or body parts of a person featured in the image or it may include the tone of clothing or another part of the image. The regions of a target tone are then applied to a computer-generated template 10, shown in Figure 4, having a plurality of doll components, such as the front and back of the arms, head, legs and torso of the doll. The step of processing an image is described in more detail using Figure 3 below.

In a preferred embodiment a user interface, shown in Figures 1 and 2, is provided to enable a user to control, to an extent, the processing of the image, including selection of target tones of the image and modification of the template. In an alternative embodiment, a user interface is not provided and the image processor automatically identifies regions of target tones and features such as facial features from the image. The determined regions of target tones are then matched to the template.

Once the regions of target tones have been applied to the component doll parts of the template electronically, the template is printed. The doll components which have had a target tone applied are selectively printed with a tone matching that of the region of a target tone. Preferably, the sheet onto which the template is printed is a 2-dimensional, beige, white, translucent or transparent sheet, but it can be of any colour. This allows accurate representation of the regions of target tones on the template. In an alternative embodiment, the pre-printed template may comprise a 'base' skin tone or other preferred colour such that the matched tones are printed over the base tone to provide an accurate representation of the regions of target tones. In another alternative embodiment, the preprinted template comprises corresponding doll parts to those on the computer-generated template. The 2-dimensional sheet allows the template to be printed rapidly, which is especially advantageous for mass production. It also allows the template to be printed from a conventional printer.

In a preferred embodiment, the face of a person featured in the image is identified by the image processor and is processed such that it is automatically applied to a facial component of the doll template. This allows an accurately proportioned representation of the person's face to be reproduced on the doll's face. In a further preferred embodiment, the user may adjust or modify the features of the face, as well as any other features or tones, to their liking to produce a fully customised doll. For example, if the user wanted to change the appearance of the doll such that it appeared intoxicated, the user may add additional colouring to the face or body parts of the doll, for instance by adding red colouring to the cheeks of the doll. Alternative emotions or appearances may also be conveyed in this way. In one embodiment, the template comprises the material which is to be cut and assembled into the completed doll. In this embodiment, the printed template can be cut using standard cutting equipment to separate each of the doll components from the template. The cut components can then be sewn, glued or brought together using any well-known technique to assemble the doll.

In an alternative embodiment, the template comprises a base layer on which a number of stickers corresponding to the doll parts are provided. The target tones are printed onto the 'sticky-back' sections of the template, which can then be peeled from the base layer and attached to a preformed doll.

In another alternative embodiment, shown in figure 2, additional components and steps are provided for the transfer of the printed tones to a fabric substrate and the subsequent cutting and assembly of the doll. The substrate may be comprised of cloth, latex or other similar material suitable for the production of dolls or clothing._Transfer is required where the printing process is a dye-sublimation printing process or similar, where ink or another pigment is to be transferred to a fabric. In this alternative embodiment, the template comprises an intermediate holding sheet onto which the matched tones are printed and held. A transfer module is provided on which the intermediate holding sheet and a fabric substrate, from which the doll will be made, are brought into 'face-to-face' contact. Preferably, heat and pressure are applied to the two layers which are now in 'face-to-face' contact such that the printed tones held on the template are fixed to the fibres of the fabric substrate. Once this fixation has been completed, the template is discarded to leave the coloured substrate which is then assembled into a complete doll.

In a preferred embodiment, the plurality of doll components are also outlined on the substrate such that they can be accurately cut from the substrate and assembled once transfer from the printed template has taken place. Preferably, the template and/or substrate are single sheets. However, in alternative embodiments, multiple sheets of material are used, on which the doll parts, matched tones and other features are to be printed.

The fabric substrate, now coloured with the matched tones, is cut to separate the component parts of the doll which may then be assembled using one of the methods described above.

The cutting and assembly of the doll, with any of the methods/systems of figures 1 and 2, may be carried out by an end user of the doll. Alternatively, cutting of the substrate is carried our prior to supplying the component parts to the end user, who may assemble the component parts themselves. In another alternative embodiment, the doll is printed, cut and either partly-assembled or fully assembled and provided to the end user in its partly- completed or completed form. During the assembling of the doll, stuffing may be inserted into a cavity produced, once the parts have been partially brought together, to fill the doll to provide the characteristic soft and flexible feel of a doll. However, a more resilient filling material may be used to give the doll more rigidity once assembled if required. Further components such as sound modules may also be introduced at this point.

In a preferred embodiment, a choice of templates is available to the user when an image has been uploaded, to provide different doll types onto which the matched tones can be printed. The scale of the doll can also be chosen and/or modified. Processing of an uploaded image from which target tones are to be applied to the computer-generated template will now be described in more detail, with reference to Figure 3. When the image processor is activated, an image, which typically features a person or object to be represented in the completed doll, is uploaded to the processor via one of the means described above. The image contains one or more regions of a target tone, a region of a target tone being an area of skin, or a feature on the skin or face. It may also be the colour of clothing. At this stage the image is displayed to the user together with a blank computer-generated template comprising the components of the doll to be printed.

The image processor preferably automatically identifies each of the regions of target tones from the image and the user may then allocate one or more of these identified regions to one or more of the doll components of the template. During printing, a tone matching that of the identified regions is printed onto the template. Even more preferably, the face of the featured person is automatically identified and allocated to a facial component of the doll template. If image processor has not automatically identified all of the desired regions of a target tone, the user can manually select further regions to be allocated to a doll component part using the user interface.

During this allocation of target tones and once completed, the computer-generated template is displayed to the user with the template's selectively coloured doll parts. In a preferred embodiment, the user interface also allows the user to modify the shape and size of the component parts of the doll, such that the figure of the doll can be customised. More preferably the user can also choose, from a library of predetermined features, additional features to apply to the template. This includes facial features, jewellery, accessories or facial hair, allowing a user to customise the appearance of the doll. This may include, for example, the facial features of a well-known person or character which can be applied to the doll parts. The library of features may contain comic or exaggerated features as well as realistic features. This further increases the customisation and originality of each doll that is produced and improves the capability for producing prototypes or replicas. Modification of the template may be used where the user wishes to exaggerate or customise a doll part or feature for a comic, dramatic or other effect. Where an outline or silhouette of the featured person is obtainable from the uploaded image, this can be utilised to modify the outline of the template. The user interface also allows additional tones to be added to the component doll parts from a predetermined and stored palate of colours. These can be applied to the doll parts to vary the appearance of the doll. In an even further preferred embodiment, pre-stored patterns can be added to the doll parts and words and pictures may also be added onto one or more of the parts.

In an alternative embodiment, a predetermined pattern is provided and applied to each of the doll parts relating to the clothing and/or limbs of the doll, and image processing of an uploaded image (plus potential addition of features from a predefined library) is carried out solely for printing of the doll's head. Image processing and printing of the dolls head may also be done separately where the body of a doll has already been produced. As well as predetermined patterns, the appearance of clothing can be printed directly onto one or more of the doll parts, for example, a pair of jeans could be printed onto the leg parts of the doll.

Once the user is satisfied with the matching of target tones to doll parts and the overall appearance of the template, the template is printed. Where the printed template is to be transferred onto a fabric substrate, inversion of the template may be required such that the printed tones are transferred to the substrate in their correct orientation.

Printing of the template is preferably carried out using dye sublimation but may also be completed via ink jet, bubble jet, laser printing, separation for lithographic, gravure, flexi plate, etching, and screen print, letterpress printing, xeroxing and associated electrographic processes or similar printing process. The printing process may also be intaglio, relief or planographic. Printing is possible on any material used to assemble the completed object and may comprise 3-dimensional printing such that contoured component parts are printed or the full doll is printed, eliminating the requirement for cutting and assembly of the doll. In another alternative embodiment, the image uploaded to the image processor is of a part of a person or a whole or part of an animal, object or of a tone and/or pattern which the user wishes to apply to the template. As well as photographs image processing of cartoons, graphic illustrations, composite photographs and composite images can also be used as a source material. Any image or illustration can be used as original source material from which tones or features can be taken. For example, a child could prepare a drawing of a relative and this would be processed and used when producing the doll. The tones used for the skin tones of the doll can be processed from an uploaded image or can be obtained from a predefined bank of tones. The process may be used to produce any sort of doll, a mannequin, soft furnishings, sheets, covers or clothing to be rapidly printed and assembled. Further, spare parts of the doll may be made, and storage of the data necessary for reprinting may be undertaken in order to provide a database of data for such parts.

Where the method is to be employed for producing a printed fabric which is subsequently used for clothing, tones from the uploaded image are processed and applied to regions of the fabric.

In a preferred embodiment, the printer is configured to print an identity mark, such as a barcode or a Quick Response (QR) code, onto a region of the template. This allows information, such as the production number or cost of each doll to be associated to the physical doll. It also allows an identity mark to be accurately positioned on a doll in an area of least inconvenience, which may vary between dolls or doll types.

Further features such as a sound module for recording and/or playback of music or a sound-bite can be included in the interior of the doll. Other features include: long heat retention materials, such as graphene, heat packs or heatable beans; mechanical motors, such as vibrating units; simulators for simulating the function of organs within the doll; colour changing devices; and lights. In a further preferred embodiment, the system further comprises a shaping unit for shaping one or more of the plurality of doll parts of the printed template and/or substrate into a 3- dimensional doll. This allows parts of the doll, such as the limbs, to be correctly shaped such that they resemble the form of real arms and legs. In a preferred embodiment, a film of material, which is pliable when subjected to heat and/or pressure and/or a chemical reaction, is applied to the reverse, non-printed surface of the fabric substrate so that components of the substrate can be shaped. A chemical reaction may include the application of a vacuum to draw the doll part into a 3- dimensional shape. The film is preferably comprised of polyurethane, graphene or a similar 'memory' material which is pliable when subjected to heat and/or pressure and/or a chemical reaction such that the doll part incorporating the film can be shaped into a three dimensional structure. Shape memory polymers are preferably used and instigated under heat, pressure and/or a chemical reaction. The film is also non-allergenic, non-toxic and fire resistance/fireproof. The film is provided in a solid, extruded form, but may alternatively be provided as a liquid which is either applied to the substrate as a liquid or is processed prior to application. In a further preferred embodiment, the film is applied to the non-printed surface of the face component of the substrate or any other part of the body, for example the hands, so that the contour of the doll's face can be shaped, although the film may be applied to any number of other components of the substrate so that each component can be shaped. In alternative embodiments, non-facial objects such as sports equipment or objects associated with the person or 'profession' of the doll may be created.

The film is preferably clear or has no colour so as not to affect the appearance of the doll. In an alternative embodiment, the film is coloured to enhance the doll's appearance. In an alternative embodiment, the film is shaped prior to adhering the film to the substrate.

An adhesive, and preferably a pressure sensitive adhesive, is provided between the substrate and film to fuse the two together. The adhesive is preferably one which is stable at room temperature, which does not easily delaminate and which is not adversely affected by detergents or soaps used in domestic environments, i.e. will not be damaged when the doll is cleaned. The adhesive is also preferably one which will retain its adhesion for the life of the doll, e.g. for 50 years or more. The adhesive is preferably comprised of a non-allergenic and non-toxic, fire retardant acrylic, silicone or polyurethane. Once cured by the application of pressure and/or heat and/or a chemical reaction, the adhesive is permanently bonded to the fabric and substrate and has a low migration through the film and substrate. Preferably, the adhesive is a thermoset adhesive. Bonding between adhesive and the film and substrate layers is preferably under pressure and at a temperature at or greater than 30 degrees Celsius and at or below 180 degrees Celsius. Even more preferably the temperature is between 30 and 150 degrees Celsius to minimise the risk of damage to the film and substrate layers. In an alternative embodiment, the temperature is greater than 180 degrees Celsius.

In an alternative embodiment, the film and substrate automatically adhere to one another when heat and/or pressure and/or a chemical reaction, such as solvents or chemical compounds, is applied. In a further alternative embodiment, an adhesive is integrally formed with either (or both) of the film and substrate.

Heat and/or pressure and/or a chemical reaction is applied to the laminate comprising the substrate, adhesive and film by a shaping tool, so that a three-dimensional shape of the film and therefore the substrate can be formed. In one embodiment where the shaping tool is configured to form the shape of a facial component, the shaping tool comprises at least two tools, dies or casts with one or more tools configured to provide a positive or substantially convex form made in the shape and 3-dimensional relief form of a face (or other part of the body). At least one further tool may have the same configuration as the first tool or, alternatively, the further tool is an inverse of the first, being substantially concave in form, or of another configuration to optimally shape the film and substrate. The shaping tools are comprised of a material, such as metals, plastics or ceramic, which can withstand the temperatures and pressures required for shaping the film.

In a preferred embodiment, the film is pliable at a temperature sufficiently above ambient temperature such that the film does not become unduly pliable in warm conditions once assembled. The film is preferably pliable at a temperature at or above 80 degrees Celsius and at or lower than 150 degrees Celsius. In a preferred embodiment, once the polymer has cooled to ambient temperature it cannot be reshaped again.

Heat may be provided externally by a separate heater. In a preferred embodiment, a heating element is embedded within at least one of the tools. Any known heating method may be used for heating the tools, however, an electrical or ceramic heating element is the preferred heating source due to the improved safety in comparison to sources such as gas or steam. Preferably, an opening is provided in one or more of the tools into which the heating element is placed. The heating element is sealed into a metal or ceramic tube. A heat sensor, which is connected to an integral or remote variable thermostat, is preferably embedded into the one or more tools to monitor and control the temperature of the heating element.

In the preferred embodiment, pressure is applied by pushing the two tools towards one another such that, with the addition of heat, the substrate and film (with or without adhesive) placed between the two tools, is made to conform to the shape of the tools; the two tools are pressed towards one another or at least one is moved towards or pressed into the other. The raised, convex features of the first tool provide a fit with concomitant convexities of the second tool, such that the shapes of facial features such as nose, chin and brow and hollows such as eye sockets are defined. In an alternative embodiment, the film is shaped prior to attachment to the substrate. As the film cools to ambient temperature, it sets in shape and does not lose shape unless similar heat and pressure is reapplied. A cooling tool may be provided in an alternative embodiment for controllably lowering the temperature of the doll part once it has been shaped.

In an alternative embodiment, a single tool is provided for defining the shape of the doll part. In a further alternative embodiment, one or more tools are provided into which a foam is injected to form the 3-dimensional form of a doll part. A number of stock facial tools may be provided for shaping the film and substrate into one of a number of different face types so that specific tools are not required for each doll produced. For example, different groups of tools may be created for dolls which have larger or smaller, narrower or wider face types. Different stock facial tools may also be created for face shapes associated with different ethnic groups of people. Tools may also be created for particular characters or animals.

In a preferred embodiment, digital or manual modelling techniques are utilised to customise the shape of the tools so that a doll may be imbued with distinct, customised facial features. Computer Aided Design (CAD) may be utilised to design particular facial shapes and expressions from which the tools are subsequently manufactured.

Photogrammetric techniques, where two or more images of a face (or other body part) are produced from different angular positions and processed by a computer, or manually using a stereo-plotter, may be used to produce an accurate representation of a person's face. Further measurement data may also be required. Manufacturing of the tools is achieved directly from a CAD file, using image scanners, or using a copying machining system where an original model is scanned and a cutting tool cuts a copy of the original model from the desired material. In alternative embodiments, the tools are manufactured by casting, in resin, wax, clay, sand or another material, a copy of a sculpted face in both original and inverse form to create intermediates from which the tools for shaping the film are subsequently made. In a further alternative embodiment, a 3- dimensional printer is provided for producing the required tools. Shaping of the plurality of doll parts is preferably alternatively carried out by placing the printed substrate over a former under tension or pressure. Heat or a shrinking agent is then applied to the substrate such that the substrate takes on the form of the former in a semipermanent or permanent manner. The shape can be fixed using glues, fabric stiffeners, shrinking 'dopes' such as cellulose acetate, butyrate and cellulose nitrate, plasticisers or similar compounds. Preferably, polyurethane foam (or a similar compound such as aerated latex, silicone or blown polyester) is applied as a filler, via injection or pouring, to the substrate. The foam is injected or poured into a cavity of the doll once it has been partially assembled and held under pressure until the foam has been formed and the doll is then left to set. Polyurethane is preferred as it produces a soft feel to the doll when pressed and returns to its original shape once pressure has ceased. Fire retardant and non-toxic properties will preferably be assessed prior to choosing such fixing or filling components.

Where a 3-dimensional printer is used, the 3-dimensional shape of the doll is formed during the printing process.

In a further embodiment, an object comprising protruding or hollowed regions is created using a larger sized tool. The object may not have to be a doll part but may resemble the figure of a face or other body part for a separate use.

Claims

1. A method of producing a plurality of doll components which, when assembled, forms a doll, comprising the steps of:

· processing an image containing one or more regions of a target tone;

• providing a template comprising a plurality of doll parts which, when assembled, form a doll; and

• selectively printing at least one of said doll parts of said template with one or more colours or tones matching the one or more regions of a target tone.

2. A method according to claim 1, comprising the further steps of identifying specific features, such as the eyes, mouth and nose of a target person in a processed image and providing specific sections on said template for said specific features.

3. A method according to either claim 1 or claim 2, comprising the further step of transferring the printed image of the template to a substrate.

4. A method according to claim 3, wherein the step of transferring the printed image to said substrate comprises placing the substrate in contact with the template and applying heat and/or pressure until the image printed on the template is fixed to the substrate.

5. A method according to either claim 3 or claim 4, wherein the substrate comprises a plurality of doll parts which correspond to the plurality of doll parts of the template.

6. A method according to any of claims 3 to 5, comprising the further step of cutting said plurality of doll parts out of said substrate.

7. A method according to any of the preceding claims, wherein the printed template is a single, 2-dimensional sheet comprising each of the plurality of doll parts.

8. A method according to any of the preceding claims, comprising the further step of providing a user interface which allows a user to select one or more modifications which, when selected, modify the size and/or shape of at least one of the plurality of doll parts of said template.

9. A method according to claim 6, comprising the further step of using said user interface to adjust the tone matching the target tone.

10. A method according to any of the preceding claims, comprising the further step of selecting one or more features, such as facial features or accessories, from a library of predetermined features for printing on one or more of the plurality of doll parts of the template.

11. A method according to any of the preceding claims, comprising the further step of printing an identity mark, such as a barcode, onto a region of the template.

12. A method according to any of the preceding claims, comprising the further step of shaping one or more of the plurality of doll parts of the printed template and/or substrate into a 3-dimensional doll.

13. A method according to any of the preceding claims, comprising the further steps of: providing a film, the film comprising a material which retains its form in ambient conditions and which becomes pliable under the application of heat and/or pressure and/or a chemical reaction; adhering said film to a non-printed surface of the doll part; and applying heat and/or pressure and/or a chemical reaction to the doll part and adhered film to shape them.

14. A method according to claim 13, comprising the step of adhering the film to a non- printed surface of one or more doll parts of the substrate.

15. A method according to either claim 13 or claim 14, wherein the film comprises a memory polymer.

16. A method according to any of claims 13 to 15, comprising the step of providing at least one shaping tool and wherein said pressure is applied to opposed surfaces of the doll parts and adhered film via said shaping tools.

17. A method according to any of claims 13 to 16, comprising the step of placing at least a region of a doll part in a vacuum to shape said doll part.

18. A method according to any of claims 13 to 17, wherein the film is pliable at a temperature in the range of 80 to 150 degrees Celsius.

19. A method according to any of claims 13 to 18, comprising the step of providing a user interface which allows a user to select one or more modifications which, when selected, modify the size and/or shape of said shaping tools.

20. A system of manufacturing and providing a doll or component part thereof comprising:

21. A system according to claim 20, further comprising a transfer module configured to transfer the one or more matched tones printed on the template to a substrate.

22. A system according to either claim 20 or claim 21, further comprising a cutting unit configured to cut out each of said doll parts from said substrate.

23. A system according to any of claims 20 to 22, further comprising a user interface configured to allow a user to modify the size and/or shape of at least one of the plurality of doll parts of said template.

24. A system according to claim 23, wherein said user interface is configured for the adjustment of the one or more matched tones.

25. A system according to any of claims 20 to 24, wherein the printer is a 3-dimensional printer.

26. A system according to any of claims 20 to 25, wherein the image processor comprises a library of predetermined features from which features, such as facial features or accessories, are printed onto a region of the template.

27. A system according to any of claims 20 to 26, wherein the printer is configured to print an identity mark, such as a barcode, onto a region of the template.

28. A system according to any of claims 20 to 27, further comprising a shaping unit for shaping one or more of the plurality of doll parts of the printed template and/or substrate into a 3-dimensional doll.

29. A system according to claim 28, further comprising a film, the film comprising a material which retains its form in ambient conditions and which becomes pliable under the application of heat and/or pressure and/or a chemical reaction; wherein the film is adhered to a non-printed surface of one or more doll parts and said shaping unit comprises a number of tools for applying heat and/or pressure and/or a chemical reaction to said film and doll parts.

30. A system according to claim 29, wherein said shaping unit comprises a heating element.

31. A system according to claim 30, wherein said heating element is embedded in at least one of said tools.

32. A system according to any of claims 29 to 31, further comprising a user interface which allows a user to select one or more modifications which, when selected, modifies the size and/or shape of said shaping unit.

33. A method of producing a printed fabric which subsequently forms a piece of clothing, comprising the steps of:

• processing an image containing one or more regions of a target tone;

• providing a template comprising a fabric; and • selectively printing at least a portion of said template with one or more colours or tones matching the one or more regions of a target tone.

34. A method of producing a plurality of doll components substantially as hereinbefore described with reference to and as illustrated by the accompanying drawings.

35. A system of manufacturing and providing a doll or component part thereof substantially as hereinbefore described with reference to and as illustrated by the accompanying drawings.

36. A method of producing a fabric substantially as hereinbefore described with reference to and as illustrate by the accompanying drawings.