Three-dimensional modeling apparatus, control apparatus, control method, and three-dimensional object

• US 8,845,050 B2
• Filed: 02/18/2010
• Issued: 09/30/2014
• Est. Priority Date: 02/26/2009
• Status: Expired due to Fees

• Current Assignee: Sony Corporation (Sony Group Corp.)
• Original Assignee: Sony Corporation (Sony Group Corp.)
• Inventors: Matsui, Takeshi, Kuzusako, Junichi, Yasukochi, Hiroyuki
• Primary Examiner(s): Le, Uyen Chau N
• Assistant Examiner(s): Smith, Chad
• Application Number:
  US12/707,898
• Publication Number:
  US 20100214333A1
• Time in Patent Office: 1,685 Days
• Field of Search: 347/8, 347/19, 347/107, 419/65
• US Class Current: 347/8
• CPC Class Codes: B29C 64/165 using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
• CPC Class Codes: B41J 25/308 with print gap adjustment mechanisms
• CPC Class Codes: H04N 1/60 Colour correction or control H04N1/54 takes precedence

Abstract

A three-dimensional modeling apparatus includes a stage, a head, an adjustment mechanism, an ejection command means, and a control means. On the stage, a powder material is accumulated. The head ejects ink to the powder material on the stage. The adjustment mechanism adjusts a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness. The ejection command means causes the ink to be ejected from the head so that the powder material is colored a plurality of colors corresponding to multilevel luminance information items in a multivalued image obtained by performing a multivalued processing of luminance with respect to a two-dimensional cross-sectional image data of a modeling target object. The control means controls the adjustment mechanism and the ejection command means so that the multivalued image is drawn for each layer thickness.

Claims

1. A three-dimensional modeling apparatus, comprising:

a stage on which a powder material is accumulated;

a supply portion for supplying the powder material;

a head to eject ink to the powder material on the stage;

a first adjustment mechanism to adjust a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness;

a second adjustment mechanism to move a portion of the powder material from the supply portion above a substantially horizontal plane;

a movement mechanism to transfer the portion of the powder material from above the substantially horizontal plane to the stage;

an ejection command means for causing the ink to be ejected from the head so that the powder material is colored a plurality of colors respectively corresponding to multilevel luminance information items in a multivalued image, the multivalued image being obtained by performing a multivalued processing of a luminance with respect to data of a two-dimensional image that is a cross-sectional image of a modeling target object, the multivalued processing being an at least two-valued processing, the ejection command means also causing the ink to be ejected in a greater density on a top surface of a first area of the powder material for at least one predetermined layer thickness than on a top surface of an equivalent second area of the powder material for the at least one predetermined layer thickness so that the first and second areas of the at least one predetermined layer thickness have different hardnesses; and

a control means to control the adjustment mechanism and the ejection command means so that the multivalued image is drawn for each layer thickness.

2. The three-dimensional modeling apparatus according to claim 1,

wherein the ink includes liquid for hardening the powder material, and

wherein the ejection command means controls an amount of the liquid ejected from the head to adjust a hardness of the three-dimensional object.

3. The three-dimensional modeling apparatus according to claim 2,

wherein the ejection command means causes the liquid to be ejected from the head by different amounts depending on areas in the three-dimensional object.

4. The three-dimensional modeling apparatus according to claim 1,

wherein the ejection command means causes the ink to be ejected from the head so that the powder material is colored in accordance with an image created by coloring the multivalued image the plurality of colors respectively corresponding to the multilevel luminance information items.

5. The three-dimensional modeling apparatus according to claim 1,

wherein, in a case where a lamination interval of cross-sectional images of the target object is larger than the predetermined layer thickness of the powder material, the ejection command means causes the ink to be ejected in accordance with the multivalued image that is subjected to an interpolation processing so that an outline of the multivalued image corresponds to an outline obtained by laminating the cross-sectional images between the lamination interval.

6. The three-dimensional modeling apparatus according to claim 1,

wherein the powder material mainly contains sodium chloride.

7. The three-dimensional modeling apparatus according to claim 1,

wherein the target object is an organism.

11. The three-dimensional modeling apparatus according to claim 1,

wherein the movement mechanism comprises a roller.

18. The three-dimensional modeling apparatus according to claim 1,

wherein the ink includes an aqueous ink having water in an amount to provide the greater density.

19. The three-dimensional modeling apparatus according to claim 1,

wherein the ink includes a colorless ink including water.

26. The three-dimensional modeling apparatus according to claim 1,

wherein an upper surface of the supply portion defines the substantially horizontal plane.

8. A control apparatus of a three-dimensional modeling apparatus including a stage on which a powder material is accumulated, a supply portion for supplying the powder material, a head to eject ink to the powder material on the stage, a first adjustment mechanism to adjust a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness, a second adjustment mechanism to move a portion of the powder material from the supply portion above a substantially horizontal plane, and a movement mechanism to transfer the portion of the powder material from above the substantially horizontal plane to the stage, the control apparatus comprising:

an ejection command means for causing the ink to be ejected from the head so that the powder material is colored a plurality of colors respectively corresponding to multilevel luminance information items in a multivalued image, the multivalued image being obtained by performing a multivalued processing of a luminance with respect to data of a two-dimensional image that is a cross-sectional image of a modeling target object, the multivalued processing being an at least two-valued processing, the ejection command means also causing the ink to be ejected in a greater density on a top surface of a first area of the powder material for at least one predetermined layer thickness than on a top surface of an equivalent second area of the powder material for the at least one predetermined layer thickness so that the first and second areas of the at least one predetermined layer thickness have different hardnesses; and

a control means to control the adjustment mechanism and the ejection command means so that the multivalued image is drawn for each layer thickness.

20. The control apparatus according to claim 8,

wherein the movement mechanism comprises a roller.

21. The control apparatus according to claim 8,

wherein the ink includes an aqueous ink having water in an amount to provide the greater density.

22. The control apparatus according to claim 8,

wherein the ink includes a colorless ink including water.

27. The control apparatus according to claim 8,

wherein an upper surface of the supply portion defines the substantially horizontal plane.

9. A control method of a three-dimensional modeling apparatus including a stage on which a powder material is accumulated, a supply portion for supplying the powder material, a head to eject ink to the powder material on the stage, a first adjustment mechanism to adjust a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness, a second adjustment mechanism to move a portion of the powder material from the supply portion above a substantially horizontal plane, and a movement mechanism to transfer the portion of the powder material from above the substantially horizontal plane to the stage, the control method comprising:

causing the ink to be ejected from the head so that the powder material is colored a plurality of colors respectively corresponding to multilevel luminance information items in a multivalued image, the multivalued image being obtained by performing a multivalued processing of a luminance with respect to data of a two-dimensional image that is a cross-sectional image of a modeling target object, the multivalued processing being an at least two-valued processing;

causing the ink to be ejected in a greater density on a top surface of a first area of the powder material for at least one predetermined layer thickness than on a top surface of an equivalent second area of the powder material for the at least one predetermined layer thickness so that the first and second areas of the at least one predetermined layer thickness have different hardnesses; and

controlling the adjustment mechanism and the ejection of the ink from the head so that the multivalued image is drawn for each layer thickness.

12. The control method according to claim 9,

wherein the movement mechanism comprises a roller.

14. The control method according to claim 9,

wherein the ink includes an aqueous ink having water in an amount to provide the greater density.

15. The control method according to claim 9,

wherein the ink includes a colorless ink including water.

28. The control method according to claim 9,

wherein an upper surface of the supply portion defines the substantially horizontal plane.

10. A three-dimensional object obtained by a three-dimensional modeling apparatus including

a stage on which a powder material is accumulated,

a supply portion for supplying the powder material,

a head to eject ink to the powder material on the stage,

a first adjustment mechanism to adjust a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness,

a second adjustment mechanism to move a portion of the powder material from the supply portion above a substantially horizontal plane,

a movement mechanism to transfer the portion of the powder material from above the substantially horizontal plane to the stage,

an ejection command means for causing the ink to be ejected from the head so that the powder material is colored a plurality of colors respectively corresponding to multilevel luminance information items in a multivalued image, the multivalued image being obtained by performing a multivalued processing of a luminance with respect to data of a two-dimensional image that is a cross-sectional image of a modeling target object, the multivalued processing being an at least two-valued processing, the ejection command means also causing the ink to be ejected in a greater density on a top surface of a first area of the powder material for at least one predetermined layer thickness than on a top surface of an equivalent second area of the powder material for the at least one predetermined layer thickness so that the first and second areas of the at least one predetermined layer thickness have different hardnesses, and

a control means to control the adjustment mechanism and the ejection command means so that the multivalued image is drawn for each layer thickness.

13. The three-dimensional object according to claim 10,

wherein the movement mechanism comprises a roller.

16. The three-dimensional object according to claim 10,

wherein the ink includes an aqueous ink having water in an amount to provide the greater density.

17. The three-dimensional object according to claim 10,

wherein the ink includes a colorless ink including water.

29. The three-dimensional object according to claim 10,

wherein an upper surface of the supply portion defines the substantially horizontal plane.

23. A three-dimensional modeling apparatus, comprising:

a stage on which a powder material is accumulated;

a head to eject ink to the powder material on the stage;

an adjustment mechanism to adjust a relative height of the stage and the head for each predetermined layer thickness so that a three-dimensional object is formed on the stage by the predetermined layer thickness;

an ejection command means for causing the ink to be ejected from the head so that the powder material is colored a plurality of colors respectively corresponding to multilevel luminance information items in a multivalued image, the multivalued image being obtained by performing a multivalued processing of a luminance with respect to data of a two-dimensional image that is a cross-sectional image of a modeling target object, the multivalued processing being an at least two-valued processing, the ejection command means also causing the ink to be ejected in a greater density on a top surface of a first area of the powder material for at least one predetermined layer thickness than on a top surface of an equivalent second area of the powder material for the at least one predetermined layer thickness, so that the first and second areas of the at least one predetermined layer thickness have different hardnesses; and

a control means to control the adjustment mechanism and the ejection command means so that the multivalued image is drawn for each layer thickness.

24. The three-dimensional modeling apparatus according to claim 23,

wherein the ink includes an aqueous ink having water in an amount to provide the greater density.

25. The three-dimensional modeling apparatus according to claim 23,

wherein the ink includes a colorless ink including water.