Patent Application
20170182710
The present invention relates to a manufacturing apparatus and a manufacturing method for manufacturing a three-dimensional fabricated object (hereinafter, a 3D-modeled object) by an additive manufacturing process, in which layers of a modeling material are stacked one over another.
Today, 3D (three-dimensional) printers are commercially available from different manufacturers, and 3D modeling has been becoming more common. It is expected that, in the near future, there will be a shift from mass-manufacturing of standardized products to manufacturing of a wide variety of products in small quantities to satisfy consumers' preferences.
On the other hand, near-field wireless communication tags, such as NFC (near-field communication) tags and RFID (radio-frequency identification) tags, and near-field wireless communication functions, such as iBeacon, are increasingly in practical use in various applications including automatic recognition. For example, a near-field wireless communication tag can be affixed to, or previously embedded in, an object; it is then possible to automatically recognize the object by wireless communication with a terminal such as a smartphone.
Conventionally, a wireless communication tag can be incorporated in an object, for example, in one of the following manners. According to Patent Literature 1, a strip of adhesive tape, called wireless communication tag tape, in which a wireless communication tag is arranged on a base with an adhesive surface, is prepared. This tape is affixed to an appropriate place on an object so that the wireless communication tag is positioned on an external surface of the object.
According to Patent Literature 2 and Patent Literature 3, a wireless communication tag is embedded inside an object (resin) by injection molding. According to Patent Literature 4, a wireless communication tag is placed between two sheet-form molded members, which are then bonded together, thereby to manufacture a 3D-modeled object that incorporates a wireless communication tag.
In the case where a wireless communication tag is used, however, information needs to be stored in the tag in a fully encrypted manner; otherwise, the information may be unauthorizedly rewritten. Besides, wireless communication tags are prone to damage caused by mechanical power, electromagnetism, etc. Also, wireless communication at a predetermined distance requires a booster antenna, which may be unable to be accommodated inside an object together with a wireless communication tag, depending on a size of the object.
To deal with such a case, there has been proposed a technique of forming, in a 3D-modeled object, a structure corresponding to an information code (an identification code) instead of a wireless communication tag. For example, according to Patent Literature 5, a powder material is cured with two binders (a metal binder, a dielectric binder), which are different from each other in physical property, to form an electrically conductive region and a dielectric region, by using which an identification code for the 3D-modeled object is formed. According to Patent Literature 6, a 3D-modeled object is manufactured by using a build material and a contrast enhancing material, and an identification code for the 3D-modeled object is formed by using the contrast enhancing material.
According to Patent Literature 7, a marking is formed inside an object while the object is being manufactured by an additive manufacturing apparatus (additive manufacturing). The marking is produced by forming a porous substructure by melting/curing a powder or a liquid and changing parameters of an energy beam used to model a 3D-modeled object. A magnetic material is inserted in the porous substructure, or an unmelted/uncured powder or liquid is sealed inside the porous substructure.
Nonpatent Literature 1 discloses a technique of embedding an information code inside an object during an additive manufacturing process. In Nonpatent Literature 2, it is reported that, when a three-dimensionally represented two-dimension code (for example, a QR code (registered trademark)) is embedded inside a modeled object, an X-ray CT scanner can perform nondestructive readout of the two-dimensional code.
Patent Literature 1: Japanese Utility Model Registration No. 3128557 (claim 1, paragraph [0014], FIG. 8, etc.)
Patent Literature 2: Japanese Patent Application Publication No. H08-276458 (claims 1 and 2, paragraphs [0013]-[0015], FIGS. 1 and 4, etc.)
Patent Literature 3: Japanese Patent Application Publication No. H11-348073 (claims 1 and 6, paragraphs [0007]-[0008], FIG. 1, etc.)
Patent Literature 4: Japanese Patent Application Publication No. 2002-007989 (claim 6, paragraph [0044], FIGS. 5(a) and 5(b), etc.)
Patent Literature 5: Japanese Patent Application Publication No. 2000-234104 (claims 1, 5, and 7, paragraph [0013], etc.)
Patent Literature 6: Japanese Translation of PCT International Application Publication No. JP-T-2007-536106 (claims 1, 2, paragraphs [0004], [0006]-[0013], [0019], etc.)
Patent Literature 7: Japanese Translation of PCT International Application Publication No. JP-T-2013-505855 (claims 1-9, paragraphs [0010]-[0030], etc.)
Nonpatent Literature 1: Karl D. D. Willis, Andrew D. Wilson, “InfraStructs: Fabricating Information Inside Physical Objects for Imaging in the Terahertz Region”, ACM Transactions on Graphics, Vol. 32, No. 4, Article 138, Publication Date: July 2013
Nonpatent Literature 2: IMAI Masataka, et al., “Detection for Matrix Barcode inside Fabricated Object via X-ray Computed Tomography (CT) Scanner”, the Institute of Electronics, Information and Communication Engineers, Technical Report, vol. 113, No. 291, EMM 2013-87, pp. 113-118, issued in November, 2013
Inconveniently, however, in the case where a structure corresponding to an information code is embedded inside a 3D-modeled object as in Patent Literatures 5 to 7 and Non-patent Literatures 1 and 2, it is impossible to tell, by just externally viewing the 3D-modeled object, where in the 3D-modeled object the structure is embedded, and hence, in order to detect the structure, the 3D-modeled object needs to be scanned completely from end to end with an external device (such as an X-ray CT device). Thus, it is impossible to quickly read information from the structure. This problem becomes more evident in a larger 3D-modeled object.
The present invention has been made to solve the above problem, and an object thereof is to provide a manufacturing apparatus and a manufacturing method for manufacturing a 3D-modeled object that permit an external device to easily find a position of an information code embedded inside a 3D-modeled object, and thereby allow quick reading of the information code embedded inside the 3D-modeled object.
According to one aspect of the present invention, a manufacturing apparatus for manufacturing a 3D-modeled object includes a modeler configured to stack layers of a modeling material one over another, and the manufacturing apparatus is configured to manufacture a 3D-modeled object by additive manufacturing performed by the modeler. Here, the manufacturing apparatus includes an information code former configured to form, inside the 3D-modeled object modeled by the modeler, an information code obtained by encoding information for identifying the 3D-modeled object, and a position code former configured to form, inside or on a surface of the 3D-modeled object, a position code obtained by encoding information indicating a formation position of the information code inside the 3D-modeled object.
By detecting a position code provided inside or on a surface of a 3D-modeled object, an external device is able to easily find a position of an information code inside the 3D-modeled object based on the detected position code, and thus to read the information code quickly.
[
[
[
[
[
[
[
[
[
[
[
An embodiment of the present invention will be described below with reference to the accompanying drawings.
3D-Modeled Object Manufacturing Apparatus:
Examples of the above-mentioned additive manufacturing process include a fused deposition modeling (FDM) process, an ink-jet process, an ink-jet binder process, a stereo-lithography (SL) process, and a selective laser sintering (SLS) process. Any of these processes can be used to manufacture a 3D-modeled object according to the embodiment, though with varying suitability depending on a size and a type of the 3D-modeled object to be manufactured. The embodiment described below deals with an example where an ink-jet process is used as an additive manufacturing process.
The 3D-modeled object manufacturing apparatus 1 includes a controlling block 10, a modeling block 20, an information code forming block 30, and a position code forming block 40. The manufacturing apparatus 1 may further include, as necessary, a removing block (unillustrated) for removing excess modeling material, etc. Each block will now be described in detail.
Controlling Block: The controlling block 10 includes a 3D data receiver 11, an embedment information receiver 12, and a controller 13. The 3D data receiver 11 is an input receiver that receives three-dimensional shape data (3D data) of a modeling target (a 3D-modeled object). The 3D data receiver 11 may be configured (as an interface) so as to acquire 3D data of a 3D-modeled object from an external computer P or the like via a communication line, or may be configured as an operated device, such as a keyboard, that directly accepts entry of 3D data of a 3D-modeled object. 3D data received by the 3D data receiver 11 is transferred to the controller 13.
The embedment information receiver 12 is an input receiver that receives information (embedment information) to be embedded in a 3D-modeled object. The embedment information may be information that helps identify a 3D-modeled object, such as a serial number, a manufacture date, a manufacture place, etc., of the 3D-modeled object. The embedment information receiver 12 may be configured (as an interface) so as to acquire embedment information from an external computer P or the like via a communication line, or may be configured as an operated device, such as a keyboard, that directly accepts entry of embedment information. Embedment information received by the embedment information receiver 12 is transferred to the controller 13.
The controller 13 includes a data processor such as a central processing unit (CPU). Based on 3D data transferred from the 3D data receiver 11, the controller 13 creates (constructs) layer-by-layer data for three-dimensional modeling of a modelling material. The controller 13 also merges modeling data of a 3D-modeled object with data of an information code, a position code, and a mark, which will be described later, to create merged data, from which the controller 13 creates (reconstructs) layer-by-layer data.
Also, the controller 13 encodes embedment information received by the embedment information receiver 12 to create an information code, and, based on the 3D data of the 3D-modeled object and shape data of the information code, the controller 13 calculates such an arrangement position of the information code where the information code fits inside the 3D-modeled object. Further, the controller 13 creates a position code by encoding information indicating a formation position of the information code inside the 3D-modeled object, and calculates an arrangement position of the position code inside the 3D-modeled object.
Also, the controller 13 controls operation of the entire apparatus including the modeling block 20, the information code forming block 30, and the position code forming block 40.
The 3D data receiver 11, the embedment information receiver 12, and the controller 13 may be implemented as hardware that operates as described above, or may be implemented as control programs that, when run, function as a 3D data receiver, an embedment information receiver, and a controller.
Modeling Block: The modeling block 20 is a modeler that models a 3D-modeled object by stacking layers of a modeling material (a first modeling material) one over another. The modeling block 20 includes a feeder 21 for feeding the modeling material (for example, ink) to a predetermined position, and a feeder moving mechanism 22 that moves the feeder 21 so that the modeling material can be fed to the target position.
The feeder 21 includes a modeling material ejector 21a and a modeling material feeder 21b. According to slice data (layer-by-layer data) acquired from the controlling block 10, the modeling material ejector 21a ejects the modeling material onto a modeling stage S, to a position determined by the feeder moving mechanism 22, with desired timing. In a case where ink is used as the modeling material, the modeling material ejector 21a is configured as an ink-jet head (an ink ejector) that ejects ink. The ink ejected onto the modeling stage S is cured by ultraviolet radiation from an unillustrated light source. The modeling material feeder 21b feeds the modeling material, which is stored in an unillustrated reservoir, to the modeling material ejector 21a. In a case where ink is used as the modeling material, the modeling material feeder 21b is configured as a tube (an ink feeder) through which the ink is fed to the ink-jet head.
The feeder moving mechanism 22 includes an X-direction mover 22a, a Y-direction mover 22b, and a Z-direction mover 22c. Based on movement control information acquired from the controlling block 10, the X-, Y-, and Z-direction movers 22a, 22b, and 22c drive an unillustrated driving mechanism, to move the feeder 21 in different directions three-dimensionally, specifically in X, Y, and Z directions, which are perpendicular to each other.
The manufacturing apparatus 1 may include one modeling material ejector 21a and one modeling material feeder 21b, or may include a plurality of each.
The above-described configuration of the modeling block 20 is one for a case where an ink-jet process is used as an additive manufacturing process, and allows for appropriate modifications depending on the type of the additive manufacturing process used. For example, in a case where stereo-lithography is used as an additive manufacturing process, the modeling block 20 can be configured to include a container in which to accommodate an ultraviolet-curing resin as a modeling material, a light source for irradiating the ultraviolet-curing resin placed on a base plate with ultraviolet light, an elevating mechanism that lowers the base plate each time the curing of a layer (a topmost layer) by irradiation with ultraviolet light is completed, etc. In any case (no matter which additive manufacturing process is used), the modeling block 20 can be configured to model a 3D-modeled object by stacking layers of the modeling material one over another.
Information Code Forming Block: The information code forming block 30 is a block (an information code former) that forms, inside a 3D-modeled object modeled by the modeling block 20, an information code obtained by encoding information (embedment information) for identifying the 3D-modeled object. For example, the embedment information is encoded into the information code through predetermined processing performed by the controller 13, and the thereby obtained information code is to be formed as a structure inside the 3D-modeled object.
The information code forming block 30 has a same configuration as the above-described modeling block 20. Specifically, the information code forming block 30 includes a feeder 31 for feeding a second modeling material (for example, ink) for forming the information code to a predetermined position, and a feeder moving mechanism 32 that moves the feeder 31 so that the second modeling material can be fed to a target position.
The feeder 31 includes a modeling material ejector 31a and a modeling material feeder 31b. Under control by the controlling block 10, the modeling material ejector 31a ejects the second modeling material onto the modeling stage S, to a position determined by the feeder moving mechanism 32, with desired timing. The modeling material feeder 31b feeds the second modeling material, which is stored in an unillustrated reservoir, to the modeling material ejector 31a.
The feeder moving mechanism 32 includes an X-direction mover 32a, a Y-direction mover 32b, and a Z-direction mover 32c. Based on movement control information acquired from the controlling block 10, the X-, Y-, and Z-direction movers 32a, 32b, and 32c drive an unillustrated driving mechanism, to move the feeder 31 in different directions three-dimensionally, specifically in the X, Y, and Z directions, which are perpendicular to each other.
Here, the first modeling material used for modeling the 3D-modeled object and the second modeling material used for modeling the information code are different from each other. For example, in a case where a resin ink (for example, an acrylate photocurable ink) is used as the first modeling material, a metallic ink (for example, one obtained by dispersing a powdered metal in a photocurable ink) is used as the second modeling material. These inks are cured by UV radiation, and based on difference between these inks in physical property (for example, density), an external device is able to distinguish the information code from the 3D-modeled object outside the information code, and read the information code.
Here, examples of the external device for reading the information code include an X-ray CT device, an ultrasonic CT device, a terahertz imaging device, a magnetic resonance imaging device, etc., but any device may be used as long as it is capable of performing non-destructive imaging of an inside of a 3D-modeled object.
Also, the first modeling material and the second modeling material may be a same material (for example, both may be a resin ink). In this case, the modeling block 20 cures the first modeling material, and the information code forming block 30 does not cure the second modeling material but leaves it uncured, whereby the information code is formed inside the 3D-modeled object. It is possible to make the first and second modeling materials different from each other in physical property (for example, density) by curing the first modeling material and leaving the second modeling material uncured, and thus, in this case, too, it is possible for the external device to distinguish the information code from the 3D-modeled object outside the information code, and read exactly the information code.
In the case where the first and second modeling materials are the same material, by providing a gap of a predetermined width around the information code formed of the second material inside a 3D-modeled object, too, it is possible to make distinction between the information code and the 3D-modeled object outside the information code, and thus to allow the external device to read the information code. In this case, however, some part of the structure constituting the information code needs to be supported inside the 3D-modeled object.
The above-described modeling block 20 may serve also as the information code forming block 30. Specifically, the modeling block 20 may be configured to eject the first modeling material and the second modeling material. In this case, the manufacturing apparatus 1 can be built compact. In particular, in the case where the first modeling material and the second modeling material are the same material, just one modeling material ejector and one modeling material feeder need to be provided corresponding to the one kind of material to be ejected, and thus it is possible to simplify the configuration of the manufacturing apparatus 1.
Position Code Forming Block: The position code forming block 40 is a block (a position code former) that forms the position code obtained by encoding information indicating the formation position of the information code inside the 3D-modeled object (information for the external device to find (detect) the position of the information code) inside or on a surface of the 3D-modeled object modeled by the modeling block 20. An example of forming the position code will be described later.
The position code forming block 40 has a same configuration as the above-described modeling block 20 and the information code forming block 30. Specifically, the position code forming block 40 includes a feeder 41 for feeding a third modeling material (for example, ink) for forming the position code to a predetermined position and a feeder moving mechanism 42 that moves the feeder 41 so that the third modeling material can be fed to the target position.
The feeder 41 includes a modeling material ejector 41a and a modeling material feeder 41b. Under control by the controlling block 10, the modeling material ejector 41a ejects the third modeling material onto the modeling stage S, to a position determined by the feeder moving mechanism 42, with desired timing. The modeling material feeder 41b feeds the third modeling material, which is stored in an unillustrated reservoir, to the modeling material ejector 41a.
The feeder moving mechanism 42 includes an X-direction mover 42a, a Y-direction mover 42b, and a Z-direction mover 42c. Based on movement control information acquired from the controlling block 10, the X-, Y-, and Z-direction movers 42a, 42b, and 42c drive an unillustrated driving mechanism, to move the feeder 41 in different directions three-dimensionally, specifically in the X, Y, and Z directions, which are perpendicular to each other.
Here, the first modeling material used for modeling the 3D-modeled object and the third modeling material used for modeling the position code are different from each other. For example, in a case where a resin ink is used as the first modeling material, a metallic ink is used as the third modeling material. These inks are cured by UV radiation, and based on difference between these inks in physical property (for example, density), the external device is able to distinguish the position code from the 3D-modeled object outside the position code, and detect the position code. Here, the second modeling material used for modeling the information code and the third modeling material used for modeling the position code may be either the same or different from each other.
Here, as the external device for detecting the position code, the same device that is used for reading the information code, such as an X-ray CT device described above, may be used.
Also, the first modeling material and the third modeling material may be the same (for example, both may be the same resin ink). In this case, the modeling block 20 cures the first modeling material, and the position code forming block 40 does not cure the third modeling material but leaves it uncured, whereby the position code is formed inside the 3D-modeled object. It is possible to make the first and third modeling materials different from each other in physical property (for example, density) by curing the first modeling material and leaving the third modeling material uncured, and thus, in this case, too, it is possible for the external device to distinguish the position code from the 3D-modeled object outside the position code, and read the position code.
Further, in the case where the first and third modeling materials are the same, by providing a gap having a predetermined width around the position code formed by using the third material inside the 3D-modeled object, it is also possible to make distinction between the position code and the 3D-modeled object outside the position code, and thus to allow the external device to read the information code. Here, however, some part of the structure formed as the position code needs to be supported inside the 3D-modeled object.
The above-described modeling block 20 may serve also as the position code forming block 40. Specifically, the modeling block 20 may be configured to eject the first modeling material and the third modeling material. In this case, the manufacturing apparatus 1 can be built compact. In particular, in the case where the first modeling material and the third modeling material are the same material, just one modeling material ejector and one modeling material feeder need to be provided corresponding to the one kind of material to be ejected, and thus it is possible to simplify the configuration of the manufacturing apparatus 1. Also, in a case where the first, second, and third modeling materials are all the same material, the modeling block 20 can serve also as both the information code forming block 30 and the position code forming block 40, and this helps achieve a maximum possible effect in terms of simplifying the configuration of the manufacturing apparatus 1. Here, it may be the information code forming block 30 alone that serves also as the position code forming block 40 (see
Example of Position Code Formation:
Thus, the position code 52 formed inside or on the surface of the 3-D modeled object 50 has any one piece of information, or any two pieces of information, selected from among the arrangement position of the information code 51 in the 3-D modeled object 50, the arrangement direction of the information code 51 as seen from the position of the position code 52, and the distance between the position code 52 and the information code 51. The position code 52 may have any combination of the three pieces of information, and may be formed to have all of the three pieces of information.
3D-Modeled Object Manufacturing Method: Next, a description will be given of a 3D-modeled object manufacturing method that employs the manufacturing apparatus 1 described above.
Step 1: 3D data of a 3D-modeled object as a modeling target is transferred from a computer P or the like to the 3D data receiver 11.
Step 2: Based on the 3D data received at Step 1, the controller 13 creates (two-dimensional) layer-by-layer data for three-dimensional modeling of the 3D-modeled object by using a modelling material. This processing is referred to as modeling data processing, or standard triangulated language (STL) processing.
Step 3: As a target of the encoding into an information code, embedment information (including a serial number, a manufacture date, etc.) for identifying the 3D-modeled object is transferred from the computer P or the like to the embedment information receiver 12.
Step 4: The controller 13 encodes, through a predetermined operation, the embedment information received by the embedment information receiver 12, to thereby generate data of the information code.
Step 5: In order to embed the generated information code inside the 3D-modeled object, based on information regarding a shape of the information code, the controller 13 calculates (determines) such an arrangement position of the information code where the information code is to be arranged inside the 3D-modeled object. Thereafter, the layer-by-layer data generated at Step 2 is merged with the data of the information code, but this process may be omitted (that is, the layer-by-layer data may be merged with the information code together with a position code at later-described Step 8).
Step 6: The controller 13 judges, from the arrangement position of the information code determined at Step 5, whether or not the information code is able to be arranged inside the 3D-modeled object. When judging affirmatively, the controller 13 proceeds directly to Step 7, while when judging negatively, the controller 13 returns to Step 4, where the controller 13 changes a size of the information code by, for example, changing an information amount or changing an information compression ratio, and then in Step 5, the controller 13 recalculates the arrangement position of the information code. The controller 13 repeats the above process until it judges that the information code can be arranged inside the 3D-modeled object. Here, the above-described changing of the information amount includes partial cutting of information included in the embedment information (for example, reducing the information amount so that only the serial number is included in the information code), for example.
Step 7: Based on the information of the arrangement position of the information code calculated at Step 5, the controller 13 creates a position code by encoding information indicating a formation position of the information code in the 3D-modeled object, and calculates (determines) an arrangement position of the position code inside or on a surface of the 3D-modeled object. Here, in a case of setting the position code to include the information of the arrangement position of the information code (for example, coordinates of the information code in an XYZ orthogonal coordinate system), the controller 13 may determine the arrangement position of the position code after creating the position code. However, in a case where the position code is set to include the information of the arrangement direction of the information code and the information of the distance between the position code and the information code, the arrangement position of the position code needs to be determined first in order to determine the arrangement direction of the information code as seen from the arrangement position of the position code and the distance between the arrangement position and the information code, and thus, the controller 13 needs to determine the arrangement position of the position code first.
Step 8: The controller 13, merges the modeling data for modeling the 3D-modeled object three-dimensionally, which has been acquired at Step 2, with the information code such that the information code is arranged at the arrangement position determined at Step 5, and merges the modeling data for modeling the 3D-modeled object three-dimensionally with the position code such that the position code is arranged at the arrangement position determined at Step 7, and creates (reconstructs) the layer-by-later data for modeling the 3D-modeled object.
Steps 9 and 10: The modeling block 20 starts to model the 3D-modeled object based on the layer-by-layer data (slice data) that the controller 13 has created (S9). Then, as illustrated in
Here, the modeling material 62 used to model the information code 71 and the position code 72 is different from the modeling material 61 used to model the 3D-modeled object, but instead, as mentioned already, these modeling materials may be the same (that is, for example, distinction between the information and position codes 71 and 72 and the 3D-modeled object may be made based on whether they are cured or uncured). Accordingly, in the additive manufacturing process, the 3D-modeled object is modeled based on the merged data acquired at Step 8, by using at least one kind of modeling material. When modeling of all the layers of the 3D-modeled object is completed (S10), the operation of manufacturing the 3D-modeled object performed by the manufacturing apparatus is completed.
Also, in the additive manufacturing process, in order to embed the information code 71 inside the 3D-modeled object, the information code is formed of the modeling material 62 in at least one layer arranged interior to outermost ones (topmost and bottommost layers) of the stacked layers of the modeling material 61. Further, in order to form the position code 72 inside or on the surface of the 3D-modeled object, the position code 72 is formed of the modeling material 62 in at least one of the stacked layers of the modeling material 61.
As has been described above, inside or on the surface of the 3D-modeled object, there is formed a position code (for example, the position code 52 or 72) that indicates the formation position of an information code (for example, the information code 51 or 71). This allows the external device to easily find the position of the information code inside the 3D-modeled object by detecting the position code. As a result, it becomes possible for the external device to read the information code without scanning the 3D-modeled object entirely from end to end, and thus to read the information code quickly. That is, with the manufacturing apparatus 1 of the present embodiment, the position code formation makes it possible to manufacture a 3D-modeled object that allows the external device to easily and quickly read an information code embedded inside the 3D-modeled object.
In the existing multifunction peripheral (MFP) business or printer business, along with the improvement in printing quality, there has arisen a social demand for a technique to prevent unauthorized printing of bank notes and the like, and also a technique to track down unauthorized copies, and these techniques have already been applied to image forming apparatuses. In the field of 3D printers, too, it is expected that a higher modeling quality will give rise to a social demand for a technique to prevent unauthorized modeling, and also a technique to track down unauthorizedly modeled objects. The capability to quickly read a structure (an information code) embedded inside a 3D-modeled object can be regarded as very advantageous in that it allows a quick performance of a next step (for example, judging whether or not the 3D-modeled object has been unauthorizedly modeled, tracking down of an unauthorizedly modeled object, etc.) based on the thus read information code.
Further, the position code formed by the position code forming block 40 includes information of at least one of the arrangement position of the information code, the arrangement direction of the information code, and the distance between the position code and the information code, and thus, by detecting the position code, the external device can accurately find the arrangement position of the information code from the position code.
Further, by modeling a 3D-modeled object with at least one kind of modeling material based on merged data obtained by merging modeling data with an information code and a position code, it is possible to securely model a 3D-modeled object having an information code and a position code formed inside thereof or on the surface thereof.
Further, in the present embodiment, a 3D-modeled object is modeled by using ink as a modeling material. Thus, the above-described effects can be obtained in a case where a 3D-modeled object is manufactured by an ink-jet process in particular out of different additive manufacturing processes.
Formation of Mark: The position code former 40 described above may serve also as a mark former. The mark former forms a mark by modeling on a surface of a 3D-modeled object, at a position near a position code. The mark indicates that a position code exists in the vicinity thereof. Here, a position code existing in the vicinity of the mark means that the distance between the position code and the mark is shorter than the distance between any other position code and the mark, and is also shorter than the distance between the information code and the mark. Here, the mark may have any shape as long as it is visible; it may be uneven shaped, or it may be colored.
At Step 7′, the controller 13 creates a mark (data) that serves as a guide to the position code created at Step 7, and calculates an arrangement position of the mark (a position that is on the surface of the 3D-modeled object and in the vicinity of the position code). Here, the mark may be created based on an input (specification on the shape of the mark) received via an unillustrated input receiver. Also, the arrangement position of the mark may be calculated based on an input (specification on the arrangement position) received via an unillustrated input receiver.
Then, at Step 8, the controller 13 merges the modeling data obtained at Step 2 with the information code and the position code, and also with the data of the mark such that the mark is arranged at the arrangement position determined at Step 7′, to thereby create merged data, and creates (reconstructs) the layer-by-layer data to be used to model the 3D-modeled object. Thereafter, based on the layer-by-layer data (slice data) created by the controller 13, in the additive manufacturing process performed at Steps 9 and 10, the modeling block 20, the information code forming block 30, and the position code forming block 40 model the 3D-modeled object, the information code, and the position code, and the position code forming block 40, which serves also as the mark former, models the mark.
Thus, with the mark formed on the surface of the 3D-modeled object, at a position in the vicinity of the position code, the external device is allowed to quickly detect the position code by scanning only the vicinity of the mark, and thus to easily find the position of the information code from the detected position code and quickly read the information code.
Also, when formed as any of the above listed signs, etc., the mark has a noticeable appearance, clearly showing where the external device should scan for the position code, and this makes it possible for the external device to detect the position code quickly.
Also, since the position code forming block 40 serves also as the mark former, the manufacturing apparatus 1 can be built compact. Here, it is also possible to provide the mark former as a device independent of the position code forming block 40. In this case, when given the same configuration (for example, a feeder and a feeder moving mechanism) as the position code former 40, the mark former can form (model) the mark by using a modeling material.
Also, by modeling a 3D-modeled object based on the merged data obtained by merging the modeling data, the information code, the position code, and the data of the mark together, it is possible to securely manufacture a 3D-modeled object having an information code, a position code, and a mark formed inside thereof or on the surface thereof. Here, the modeling materials used to model the 3D-modeled object, the information code, the position code, and the mark may all be the same, or may be different from each other. Thus, by using at least one kind of modeling material, it is possible to securely manufacture a 3D-modeled object having an information code, a position code, and a mark formed inside thereof or on the surface thereof.
Other Modeling Methods:
For example, in a case where the modeling block 20 models a 3D-modeled object by a fused deposition modeling (FDM) process, the modeling is performed by melting a thread-like resin (filament) with heat, and extruding the melted resin from a dissolution head to stack it on a platform. As the resin, there can be used a resin higher in viscosity than ink used in an ink-jet process, such as an ABS resin (acrylonitrile-butadiene-styrene copolymerization synthetic resin). Thus, by performing the additive manufacturing process by using such a highly viscous resin, it becomes possible to model a 3D-modeled object while forming spaces to be an information code 71 and a position code 72 inside the 3D-modeled object. Of the above-mentioned spaces, one that forms the information code 71 is a closed space (this is because the information code 71 is formed inside the 3D-modeled object), but one that forms the position code 72 may be either a closed space or an open space (this is because the position code 72 is formed inside or on the surface of the 3D-modeled object).
Since the spaces surrounded by the modeling material 61 become the information code 71 and the position code 72, there is no need of preparing a modeling material for forming an information code and a position code besides the modeling material 61 used for modeling the 3D-modeled object. Further, since there is no need of providing an ejector that ejects a modeling material for forming an information code and a position code, it becomes possible to omit the information code forming block 30 and the position code forming block 40, and thus to simplify the configuration of the manufacturing apparatus 1.
The above-described 3D-modeled object manufacturing apparatus and method for manufacturing a 3D-modeled object can be expressed as follows, and provide effects as described below.
The above-described 3D-modeled object manufacturing apparatus includes a modeler that stacks layers of modeling material one over another, and manufactures a 3D-modeled object by an additive manufacturing process performed by the modeler. The manufacturing apparatus includes an information code former that forms, inside the 3D-modeled object modeled by the modeler, an information code obtained by encoding information for identifying the 3D-modeled object, and a position code former that forms, inside or on a surface of the 3D-modeled object, a position code obtained by encoding information indicating a formation position of the information code inside the 3D-modeled object.
With this configuration, the information code for identifying the 3D-modeled object is formed (embedded), by the information code former, inside the 3D-modeled object that is modeled by the modeler. And, the position code, which is obtained by encoding information indicating the formation position of the information code inside the 3D-modeled object, is formed, by the position code former, inside or on a surface of this 3D-modeled object. This makes it possible for an external device (for example, an X-ray CT device) to detect the position code to thereby easily find a position of the information code inside the 3D-modeled object based on the position code. Accordingly, the external device does not need to scan the entire 3D-modeled object in order to read the information code, and thus can read the information code quickly.
According to another aspect of the present invention, a method for manufacturing a 3D-modeled object includes an additive manufacturing process of manufacturing a 3D-modeled object by stacking layers of a modeling material one over another. In the additive manufacturing process, an information code obtained by encoding information for identifying the 3D-modeled object is formed in at least one layer arranged interior to outermost ones of the stacked layers of the modeling material, to thereby form the information code inside the 3-D modeled object, and a position code obtained by encoding information indicating a formation position of the information code is formed in at least one of the stacked layers of the modeling material to thereby form the position code inside or on a surface of the 3D-modeled object.
In the additive manufacturing process, an information code is formed inside a 3D-modeled object, and a position code is formed inside or on a surface of a 3D-modeled object. Thus, in the same manner as described above, by detecting the position code, an external device is able to easily find the position of the information code inside the 3D-modeled object based on the detected position code, and thus to read the information code more quickly than in the case of scanning the entire 3D-modeled object.
The position code former forms the position code, by using a modeling material, inside or on the surface of the 3D-modeled object, and the modeling material for modeling the 3D-modeled object and the modeling material for modeling the position code may be different. Also, in the additive manufacturing process, the position code may be formed inside or on the surface of the 3D-modeled object by using a modeling material that is different from the modeling material used for modeling the 3D-modeled object.
The 3D-modeled object and the position code are formed of different modeling materials, and thus are different from each other in physical property (for example, density). This makes it possible to make a clear distinction between the 3D-modeled object and the position code formed inside or on the surface of the 3D-modeled object, and thus to allow secure detection of the position code by the external device.
The position code former may form the position code inside the 3D-modeled object by using a modeling material, the modeling material may be the same as the modeling material that is used for modeling the 3D-modeled material, and the position code may be formed inside the 3D-modeled object by making the modeling material used to model the 3D-modeled object different in physical property from the modeling material used to model the position code.
Also, in the additive manufacturing process, the position code may be formed inside the 3D-modeled object with the same modeling material as the one used for modeling the 3D-modeled object by making the modeling material used to model the 3D-modeled object different in physical property from the modeling material used to model the position code.
Even when the modeling material used to model a 3D-modeled object is the same as the modeling material used to model a position code, a position code is formed inside a 3D-modeled object by making them different from each other in physical property (for example, density) by, for example, curing the former and leaving the latter uncured. In this case, too, it is possible to make a clear distinction between the 3D-modeled object and the position code formed inside thereof, and thus for the external device to securely detect the position code.
The modeler may serve also as at least either of the information code former and the position code former. In this case, the manufacturing apparatus can be built compact.
The information code former may serve also as the position code former. In this case, the manufacturing apparatus can be built more compact than in a case where they are configured separately.
It is preferable for the position code to include information of at least one of an arrangement position of the information code in the 3D-modeled object, an arrangement direction of the information code as seen from a position of the position code, and a distance between the position code and the information code.
In this case, by detecting a position code, the external device can accurately find, based on the position code, the arrangement position (embedment position) of the information code in the entire 3D-modeled object.
The manufacturing apparatus described above may further include a mark former that forms a mark on the surface of the 3D-modeled object, at a position in the vicinity of the position code, the mark indicating that the position code exists in the vicinity thereof. Also, in the additive manufacturing process, there may be further formed a mark on the surface of the 3D-modeled object, at a position in the vicinity of the position code, the mark indicating that the position code exists in the vicinity thereof.
In this case, by scanning the vicinity of the mark, the external device can detect the position code quickly.
The position code former may serve also as the mark former. In this case, the manufacturing apparatus can be built compact.
The mark may be formed as any one of the following: a letter, a numeral, a symbol, a sign, a seal, an emblem, a crest, a logo, a signature, a diagram, a characteristic shape, a pattern, and a combination of any of these. In this case, since the mark has a noticeable appearance, it is possible to have the external device scan only the vicinity of the mark to detect the position code.
The manufacturing method described above may further include a process of encoding information for identifying the 3D-modeled object into the information code, a process of determining an arrangement position of the information code inside the 3D-modeled object based on information of a shape of the information code, a process of encoding information indicating a formation position of the information code in the 3D-modeled object into the position code and determining an arrangement position of the position code inside or on a surface of the 3D-modeled object, and a process of creating merged data by merging modeling data for modeling the 3D-modeled object three-dimensionally with the information code and the position code such that the information code and the position code are arranged at their determined arrangement positions, and in the additive manufacturing process, the 3D-modeled object may be modeled based on the merged data by using at least one kind of modeled material.
By forming the 3D-modeled object based on the merged data obtained by merging the modeling data with the information code and the position code by using at least one kind of modeling material, it is possible to securely model the 3D-modeled object having the information code and the position code, the information code and the position code being formed inside or on the surface the 3D-modeled object.
The manufacturing method described above may further include a process of encoding information for identifying the 3D-modeled object into the information code, a process of determining an arrangement position of the information code inside the 3D-modeled object based on information of a shape of the information code, a process of encoding information indicating a formation position of the information code in the 3D-modeled object into the position code and determining an arrangement position of the position code inside or on a surface of the 3D-modeled object, a process of creating data of the mark, and determining an arrangement position of the mark on the surface of the 3D-modeled object, and a process of creating merged data by merging modeling data for modeling the 3D-modeled object three-dimensionally with the information code, the position code, and the data of the mark such that the information code, the position code, and the mark are arranged at their determined arrangement positions, and in the additive manufacturing process, the 3D-modeled object may be modeled based on the merged data by using at least one kind of modeling material.
By modeling the 3D-modeled object based on the merged data obtained by merging the modeling data, the information code, the position code, and data of the mark together by using at least one kind of modeling material, it is possible to securely manufacture the 3D-modeled object having the information code, the position code, and the mark formed inside thereof or on the surface thereof.
The manufacturing method described above may further include a process of receiving information for identifying the 3D-modeled object as a target of the encoding into the information code. In this case, an information code can be obtained by encoding the received information (identification information).
The modeler may include an ink ejector that ejects ink as the modeling material, and an ink feeder that feeds the ink into the ink ejector. Also, in the additive manufacturing process, the 3D-modeled object may be modeled by using ink as the modeling material.
In this case, it is possible to obtain the above-mentioned effects in a case where a 3D-modeled object is manufactured by an ink-jet process in particular out of different additive manufacturing processes.
The modeler may serve also as the position code former, and may form the position code by stacking layers of the modeling material excluding a part to be the position code. Also, in the additive manufacturing process, the position code may be formed by stacking layers of the modeling material one over another excluding a part to be the position code.
Since a space (open space or closed space) surrounded by the modeling material becomes the position code, there is no need of preparing a modeling material for forming the position code besides the modeling material for modeling the 3D-modeled object. Also, the ejector that ejects the modeling material for forming the position code does not need to be provided, and this helps achieve a simple apparatus configuration.
A manufacturing apparatus and a manufacturing method according to the present invention find applications in the manufacture of 3D-modeled objects by use of an additive manufacturing process.
1 manufacturing apparatus
20 modeling block (modeler)
21
a modeling material ejector (ink ejector)
21
b modeling material feeder (ink feeder)
30 information code forming block (information code former)
40 position code forming block (position code former, mark former)
50 3D-modeled object
51 information code
52 position code
53 mark
61 modeling material
62 modeling material
71 information code
72 position code
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014-082533 | Apr 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/055799 | 2/27/2015 | WO | 00 |
