FORMING METHOD, FORMING SYSTEM, AND FORMING APPARATUS

• US 20180036951A1
• Filed: 07/25/2017
• Published: 02/08/2018
• Est. Priority Date: 08/08/2016
• Status: Active Grant

• Current Assignee: Mimaki Engineering Co., Ltd.
• Original Assignee: Mimaki Engineering Co., Ltd.
• Inventors: HARAYAMA, Kenji
• Granted Patent: US 10,811,246 B2
• Time in Patent Office: Days
• CPC Class Codes: B08B 3/10 with additional treatment of the liquid or of the object being cleaned, e.g. by heat, by electricity or by vibration
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/236 for motion in a direction within the plane of a layer
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2995/0021 Multi-coloured
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B41J 2/01 Ink jet
• CPC Class Codes: H01L 21/02041 Cleaning
• CPC Class Codes: H01L 21/02052 Wet cleaning only H01L21/02085 takes precedence
• CPC Class Codes: H01L 21/67051 using mainly spraying means, e.g. nozzles
• CPC Class Codes: H01L 21/68764 characterised by a movable susceptor, stage or support, others than those only rotating on their own vertical axis, e.g. susceptors on a rotating caroussel
• CPC Class Codes: H04N 1/4052 by error diffusion, i.e. transferring the binarising error to neighbouring dot decisions

Abstract

A forming method for forming a three-dimensional object includes a generating step including, based on model data representing the object, generating cross-section data respectively representing cross-sections of the object that are different in position in a cross-section arrangement direction. An executing step includes discharging build materials respectively based on the cross-section data. When at least a portion of the object is to be colored: the cross-section data include colored region data respectively representing cross-sections of a colored region of the object that is to be colored based on a color of a surface of the object; the executing step includes forming the colored region using the build materials based on the colored region data; the model data represents the color of the surface of the object in a multi-level gradation; and each of the colored region data represents a color in a lower level of gradation.

Claims

1. A forming method for forming a three-dimensional object, the method comprising:

a cross-section data generating step of, based on model data representing the object to be formed, generating a plurality of pieces of cross-section data respectively representing cross-sections of the object to be formed that are different from each other in position in a predetermined cross-section arrangement direction in which the cross-sections are arranged; and

a formation executing step of discharging build materials respectively based on the plurality of pieces of cross-section data so as to form the object,

wherein when at least a portion of the object is to be colored,

the plurality of pieces of cross-section data generated in the cross-section data generating step comprise a plurality of pieces of colored region data respectively representing cross-sections of a colored region of the object that is to be colored based on a color of a surface of the object, each of the cross-sections of the colored region corresponding to the colored portion at least on a surface of each of the cross-sections of the colored region,

the formation executing step comprises forming the colored region using the build materials based on the colored region data, the build materials each comprising a coloring build material,

the model data represents the color of the surface of the object in a multi-level gradation, and

each of the plurality of pieces of colored region data generated in the cross-section data generating step represents a color in a lower level of gradation than the multi-level gradation of the color of the surface of the object represented in the model data, the lower level of gradation being obtained by reducing the multi-level gradation.

2. The forming method according to claim 1, wherein the cross-section data generating step comprises

a first intermediate data generating step of generating, based on the model data, first intermediate data representing the object colored over a thickness region of the object, the thickness region being disposed under the surface of the object and comprising a predetermined thickness from the surface of the object in a normal direction of the object approximately perpendicular to the surface of the object,

a second intermediate data generating step of generating second intermediate data by dividing the object represented in the first intermediate data into a plurality of cross-sections in the cross-section arrangement direction, and

an error diffusion processing step of reducing, using error diffusion, levels of color gradation of the plurality of cross-sections in the second intermediate data so as to generate the plurality of pieces of cross-section data.

3. The forming method according to claim 1, wherein the cross-section data generating step comprises distributing an error to be distributed in the error diffusion at least to a first portion of the colored region and a second portion of the colored region, the first portion corresponding to one piece of cross-section data among the plurality of pieces of cross-section data, the second portion corresponding to another piece of cross-section data that is among the plurality of pieces of cross-section data and that abuts the one piece of cross-section data in the cross-section arrangement direction.

4. The forming method according to claim 1,

wherein so as to form the object, the formation executing step comprises

causing an extrusion head that extrudes the build materials to perform a main scanning operation that comprises moving in a predetermined main scanning direction while discharging the build materials, and

causing the extrusion head to perform deposition direction scanning that comprises moving relative to the object while the object is being formed in a deposition direction in which the build materials are deposited, and

wherein the cross-section data generating step comprises distributing an error to be distributed in error diffusion in the main scanning direction, in a sub-scanning direction approximately orthogonal to the main scanning direction, and in the deposition direction.

5. The forming method according to claim 4, wherein the cross-section data generating step comprises

distributing the error in the main scanning direction according to a first distribution ratio of the error, the first distribution ratio being set based on a first forming resolution in the main scanning direction,

distributing the error in the sub-scanning direction according to a second distribution ratio of the error, the second distribution ratio being set based on a second forming resolution in the sub-scanning direction, and

distributing the error in the deposition direction according to a third distribution ratio of the error, the third distribution ratio being set based on a third forming resolution in the deposition direction.

6. The forming method according to claim 4, wherein the cross-section data generating step comprises causing the third distribution ratio of the error in the deposition direction to be different from the first distribution ratio of the error in the main scanning direction and the second distribution ratio of the error in the sub-scanning direction.

7. The forming method according to claim 4,

wherein the formation executing step comprises causing the extrusion head to extrude the build materials to respective positions of voxels arranged at intervals that are based on a forming resolution, and

wherein the cross-section data generating step comprises

when the levels of gradation are reduced in the error diffusion and the error occurs at a position of each of the voxels, distributing the error to a position of another voxel adjacent to the each of the voxels, and

causing a number of the voxels arranged in a range over which the error is distributed in the deposition direction to be different from the number of the voxels arranged in a range over which the error is distributed in the main scanning direction and different from the number of the voxels arranged in a range over which the error is distributed in the sub-scanning direction.

8. The forming method according to claim 4, wherein the cross-section data generating step comprises causing a distance of a range over which the error is distributed in the error diffusion to be uniform among the main scanning direction, the sub-scanning direction, and the deposition direction.

9. The forming method according to claim 1, wherein the cross-section data generating step comprises performing error diffusion to half-tone the color represented in the multi-level gradation in the model data into a binary gradation so as to generate the plurality of pieces of cross-sections data.

10. The forming method according to claim 1, wherein after the multi-level gradation of the color represented in the model data has been reduced using error diffusion, the formation executing step comprises representing a half-tone color using the build material of the colored portion of the object.

11. The forming method according to claim 1, wherein the formation executing step comprises forming the colored object using a plurality of extrusion heads configured to extrude build materials of colors different from each other.

12. The forming method according to claim 1, wherein the build materials each comprise an ultraviolet curable ink that is curable under ultraviolet light.

13. The forming method according to claim 1, wherein the formation executing step comprises flattening layers of the build materials using a flattener so as to adjust a thickness of each of the layers to a predetermined thickness, the layers being respectively formed based on the plurality of pieces of cross-section data.

16. The forming method according to claim 2, wherein the cross-section data generating step comprises distributing an error to be distributed in the error diffusion at least to a first portion of the colored region and a second portion of the colored region, the first portion corresponding to one piece of cross-section data among the plurality of pieces of cross-section data, the second portion corresponding to another piece of cross-section data that is among the plurality of pieces of cross-section data and that abuts the one piece of cross-section data in the cross-section arrangement direction.

17. The forming method according to claim 2,

wherein so as to form the object, the formation executing step comprises

causing an extrusion head that extrudes the build materials to perform a main scanning operation that comprises moving in a predetermined main scanning direction while discharging the build materials, and

causing the extrusion head to perform deposition direction scanning that comprises moving relative to the object while the object is being formed in a deposition direction in which the build materials are deposited, and

wherein the cross-section data generating step comprises distributing an error to be distributed in error diffusion in the main scanning direction, in a sub-scanning direction approximately orthogonal to the main scanning direction, and in the deposition direction.

18. The forming method according to claim 3,

wherein so as to form the object, the formation executing step comprises

causing an extrusion head that extrudes the build materials to perform a main scanning operation that comprises moving in a predetermined main scanning direction while discharging the build materials, and

causing the extrusion head to perform deposition direction scanning that comprises moving relative to the object while the object is being formed in a deposition direction in which the build materials are deposited, and

wherein the cross-section data generating step comprises distributing an error to be distributed in error diffusion in the main scanning direction, in a sub-scanning direction approximately orthogonal to the main scanning direction, and in the deposition direction.

19. The forming method according to claim 16,

wherein so as to form the object, the formation executing step comprises

causing an extrusion head that extrudes the build materials to perform a main scanning operation that comprises moving in a predetermined main scanning direction while discharging the build materials, and

causing the extrusion head to perform deposition direction scanning that comprises moving relative to the object while the object is being formed in a deposition direction in which the build materials are deposited, and

wherein the cross-section data generating step comprises distributing an error to be distributed in error diffusion in the main scanning direction, in a sub-scanning direction approximately orthogonal to the main scanning direction, and in the deposition direction.

20. The forming method according to claim 17, wherein the cross-section data generating step comprises

distributing the error in the main scanning direction according to a first distribution ratio of the error, the first distribution ratio being set based on a first forming resolution in the main scanning direction,

distributing the error in the sub-scanning direction according to a second distribution ratio of the error, the second distribution ratio being set based on a second forming resolution in the sub-scanning direction, and

distributing the error in the deposition direction according to a third distribution ratio of the error, the third distribution ratio being set based on a third forming resolution in the deposition direction.

14. A forming system configured to form a three-dimensional object, the forming system comprising:

a cross-section data generator configured to, based on model data representing the object to be formed, generate a plurality of pieces of cross-section data respectively representing cross-sections of the object to be formed that are different from each other in position in a predetermined cross-section arrangement direction in which the cross-sections are arranged; and

a formation executor configured to extrude build materials respectively based on the plurality of pieces of cross-section data so as to form the object,

wherein when at least a portion of the object is to be colored,

the plurality of pieces of cross-section data generated by the cross-section data generator comprise a plurality of pieces of colored region data respectively representing cross-sections of a colored region of the object that is to be colored based on a color of a surface of the object, each of the cross-sections of the colored region corresponding to the colored portion at least on a surface of each of the cross-sections of the colored region,

the formation executor comprises forming the colored region using the build materials based on the colored region data, the build materials each comprising a coloring build material,

the model data represents the color of the surface of the object in a multi-level gradation, and

each of the plurality of pieces of colored region data generated by the cross-section data generator represents a color in a lower level of gradation than the multi-level gradation of the color of the surface of the object represented in the model data, the lower level of gradation being obtained by reducing the multi-level gradation.

15. A forming apparatus configured to form a three-dimensional object by discharging build materials respectively based on a plurality of pieces of cross-section data received from a cross-section data generator, the plurality of pieces of cross-section data respectively representing cross-sections of the object to be formed that are different from each other in position in a predetermined cross-section arrangement direction in which the cross-sections are arranged,

wherein the cross-section data generator is configured to generate the plurality of pieces of cross-section data based on model data representing the object to be formed, and

wherein when at least a portion of the object is to be colored,

the plurality of pieces of cross-section data received from the cross-section data generator comprise a plurality of pieces of colored region data respectively representing cross-sections of a colored region of the object that is to be colored based on a color of a surface of the object, each of the cross-sections of the colored region corresponding to the colored portion at least on a surface of each of the cross-sections of the colored region,

the forming apparatus is configured to form the colored region using the build materials based on the colored region data, the build materials each comprising a coloring build material,

the model data represents the color of the surface of the object in a multi-level gradation, and

each of the plurality of pieces of colored region data generated by the cross-section data generator represents a color in a lower level of gradation than the multi-level gradation of the color of the surface of the object represented in the model data, the lower level of gradation being obtained by reducing the multi-level gradation.