A mattress manufacturing method based on 3D scanning and 3D printing

Abstract

The present invention provides a mattress manufacturing method based on three-dimensional scanning and 3D printing, belonging to the field of bedding manufacturing technology. This method aims to solve the problem that existing mattress manufacturing technology cannot customize mattresses according to the user's body shape and sleeping habits. The present invention comprises the following steps: S1, collecting the user's body shape data, mass, and sleeping habits; S2, constructing a simplified human body model based on the user's body shape data, importing the simplified human body model into simulation software for assignment and solution to obtain pressure data and pressure distribution diagrams for the interface between the person and the bed for each sleeping position; S3, superimposing the pressure data of the interface between the person and the bed for each sleeping position to obtain combined pressure data and generate a combined pressure distribution diagram; S4, constructing a mattress model with a dot matrix structure, adjusting the dot matrix structure of the corresponding area according to the combined pressure data, and obtaining a printed mattress model; S5, using a 3D printer to print the mattress model to obtain a 3D printed mattress. This method enables personalized customization of mattresses for one person and one bed.

Description

Technical Field

[0001] The present invention relates to the technical field of bedding manufacturing, and in particular to a mattress manufacturing method based on three-dimensional scanning and 3D printing. Background Art

[0002] Mattresses are essential daily furniture and are the material basis for ensuring users' sleep quality. A good mattress design needs to meet the comfort requirements of different groups of people. There are many factors that determine the comfort of a mattress. In addition to subjective feelings, its inherent characteristics, such as the pressure distribution on the mattress interface, the spinal morphology under different sleeping positions, and the mechanical properties of the mattress material, are the focus of research in mattress design.

[0003] Currently, traditional mattresses are primarily categorized as palm, sponge, spring, latex, and composite mattresses. Numerous studies have shown that softer mattresses improve deep sleep compared to palm, but softer mattresses require tailored support for different body positions. Otherwise, a softer mattress can cause symptoms like lumbar pain and spinal curvature. While some existing spring mattresses can be designed with varying spring firmness to meet support requirements, it's difficult for users of varying heights and weights to achieve the optimal experience on the same product. Therefore, the consumer market urgently needs a customized mattress manufacturing method.

[0004] With the development of technology, the combination of 3D scanning and 3D printing technology has brought new manufacturing processes and methods for customized furniture and personal health products. This technology has been widely used in oral correction, sports protection, health care and other fields.

[0005] Therefore, in view of the shortcomings of traditional mattresses in manufacturing technology and design and the application of 3D scanning and 3D printing technology, there is an urgent need to apply 3D scanning and 3D printing to the manufacture of mattresses. Summary of the Invention

[0006] The technical problems to be solved by the present invention are:

[0007] The existing mattress manufacturing technology cannot customize the mattress according to the user's body shape and sleeping habits.

[0008] The present invention is to solve the above technical problems using the following technical solutions:

[0009] The present invention provides a mattress manufacturing method based on three-dimensional scanning and 3D printing, comprising the following steps:

[0010] S1. Scanning the user's body with a non-contact 3D scanner to obtain the user's body shape data, including body contour data, body proportion data, body volume data, and center of gravity distribution, and collecting the user's mass and sleeping posture data;

[0011] S2. Reconstructing, optimizing, and simplifying the obtained body shape data to obtain a simplified human body model. Importing the simplified human body model into simulation software, assigning parameters and meshing the simplified human body model. Adjusting the simplified human body model to different sleeping positions according to the user's sleeping habits, applying boundary conditions to obtain human body simulation models for different sleeping positions, and solving to obtain pressure data of the human-bed interface for each sleeping position and generating a pressure distribution map of the human-bed interface.

[0012] S3. Using data processing software, superimpose the pressure data of the bed interface of each sleeping position, take the maximum pressure value of the overlapping parts of the human body, obtain combined pressure data and generate a combined pressure distribution map;

[0013] S4. Construct a mattress model with a lattice structure, superimpose the obtained combined pressure distribution map with the lattice structure mattress model, and adjust the lattice structure of the corresponding area according to the combined pressure data to change the support and softness of the corresponding area to obtain a printed mattress model;

[0014] S5. Use slicing software to slice the printed mattress model to obtain a processing file, add the mattress raw material to the 3D printer and import the processing file for printing to obtain a 3D printed mattress based on the three-dimensional data.

[0015] Optionally, the S2 includes the following steps:

[0016] S21. Reconstruct and optimize the obtained body shape data to obtain a human body model. Without changing the outline and spinal curve of the human body model, hide some detailed features to obtain a simplified human body model.

[0017] S22, importing the obtained simplified human body model into simulation software, and setting parameters for mass, center of gravity distribution, and human body surface hardness;

[0018] S23. Divide the simplified human body model into a grid. Adjust the simplified human body model to different sleeping positions according to the user's sleeping habits. Apply boundary conditions to obtain human body simulation models for different sleeping positions. Submit the obtained simulation models for each sleeping position to the solver for solution. Obtain pressure data of the human-bed interface for each sleeping position and generate a human-bed interface pressure map.

[0019] Optionally, the method for determining the human body surface hardness in S22 is: fitting the human body surface hardness and the human body BMI value to obtain a fitting curve, calculating the user's human body BMI value based on the user's body shape data, and substituting the BMI value into the fitting curve to solve the human body surface hardness value.

[0020] Optionally, the simulation software used in S22 is comsol simulation software.

[0021] Optionally, the data processing software used in S3 is Origin software.

[0022] Optionally, the lattice structure in S4 includes a plurality of lattice structure units, each lattice structure unit is a regular dodecahedron structure unit connected to each other by connecting beams, and the nodes of each regular dodecahedron structure unit are connected by connecting beams.

[0023] Optionally, the lattice structure of the corresponding area is adjusted according to the combined pressure data in S4 to adjust the support and softness of the corresponding area. The specific implementation process is: taking the maximum pressure value in the combined pressure distribution diagram as the upper limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is reduced; the minimum pressure value is the lower limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is increased, and the lattice unit structure in the remaining areas adjusts the diameter of the connecting beam according to the comparison between the pressure value and the maximum pressure and the minimum pressure.

[0024] Optionally, the non-contact three-dimensional scanner in S1 is one of a line structured light three-dimensional scanner, a laser scanner, a photographic scanner, and a white light scanner.

[0025] Optionally, the slicing software used in S5 is one of CURA, magics, netfabb, and simplify3D slicing software.

[0026] Optionally, the raw material used to construct the lattice structure is one of silicone, latex, polyurethane, polyurethane acrylic resin, tetraphenylethylene, and nylon elastomer.

[0027] Compared with the prior art, the present invention has the following beneficial effects:

[0028] The present invention provides a mattress manufacturing method based on three-dimensional scanning and 3D printing. 1) The method of the present invention fundamentally solves the problem of difficulty in customizing existing mattresses, provides a new idea for mattress customization, and can realize personalized customization of one bed for one person. The digital production process simplifies the customization process and greatly reduces labor costs and uncontrollable factors.

[0029] 2) The user's body shape data is quickly acquired through 3D scanning, and the pressure distribution of the user's bed interface is accurately calculated through simulation analysis. The mattress support structure is adjusted according to the pressure distribution in different areas to provide the user with good support and comfort experience, which is conducive to improving the user's sleep quality and alleviating local soreness during sleep.

[0030] 3) At the same time, the 3D printed customized mattress produced by this method can provide special groups such as long-term bedridden patients, spinal curvature, and disabled people with balanced, stable, and cushioning and shock-absorbing mattress functions according to their bed habits, ensuring their comfort and safety. In addition, the mattress manufactured by the method of the present invention has good air permeability and can effectively prevent bedsores.

[0031] 4) The 3D printed mattress manufactured by the present invention can achieve millimeter-level support force zoning, and the support force of the mattress can be adjusted by changing the lattice structure without affecting the processing flow and process.

[0032] 5) The method of the present invention is widely applicable to 3D printing processes. Currently, mainstream 3D printing equipment on the market can use this method to produce 3D printed mattresses, which has high market value in driving the 3D printing service industry and raw material processing companies. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 Flowchart of a mattress manufacturing method based on three-dimensional scanning and 3D printing according to an embodiment of the present invention;

[0034] Figure 2 The human body model and the pre-processed human body model diagram in the embodiment of the present invention;

[0035] Figure 3 A model diagram after meshing in an embodiment of the present invention;

[0036] Figure 4 This is a diagram showing pressure distribution on the bed interface for different sleeping positions in an embodiment of the present invention;

[0037] Figure 5 This is a fitting diagram of human body surface hardness and human body BMI value in an embodiment of the present invention;

[0038] Figure 6 A diagram showing a mattress base model in an embodiment of the present invention;

[0039] Figure 7 An enlarged view of the dot matrix unit structure in an embodiment of the present invention;

[0040] Figure 8 A diagram of a mattress model with a lattice structure in an embodiment of the present invention;

[0041] Figure 9 This is a 3D printed mattress model in an embodiment of the present invention. DETAILED DESCRIPTION

[0042] In the description of the present invention, it should be noted that the terms "first," "second," and "third" mentioned in the embodiments of the present invention are used for descriptive purposes only and are not to be understood as indicating or implying relative importance or implicitly specifying the number of the technical features indicated. Therefore, a feature specified as "first," "second," or "third" may explicitly or implicitly include one or more of such features.

[0043] In order to make the above-mentioned objects, features and advantages of the present invention more obvious and easy to understand, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0044] Specific implementation plan 1: Combined Figures 1 to 9 As shown, the present invention provides a mattress manufacturing method based on three-dimensional scanning and 3D printing, comprising the following steps:

[0045] S1. Scanning the user's body with a non-contact 3D scanner to obtain the user's body shape data, including body contour data, body proportion data, body volume data, and center of gravity distribution, and collecting the user's mass and sleeping posture data;

[0046] S2. Reconstructing, optimizing, and simplifying the obtained body shape data to obtain a simplified human body model. Importing the simplified human body model into simulation software, assigning parameters and meshing the simplified human body model. Adjusting the simplified human body model to different sleeping positions according to the user's sleeping habits, applying boundary conditions to obtain human body simulation models for different sleeping positions, and solving to obtain pressure data of the human-bed interface for each sleeping position and generating a pressure distribution map of the human-bed interface.

[0047] S3. Using data processing software, superimpose the pressure data of the bed interface of each sleeping position, take the maximum pressure value of the overlapping parts of the human body, obtain combined pressure data and generate a combined pressure distribution map;

[0048] S4. Construct a mattress model with a lattice structure, superimpose the obtained combined pressure distribution map with the lattice structure mattress model, and adjust the lattice structure of the corresponding area according to the combined pressure data to change the support and softness of the corresponding area to obtain a printed mattress model;

[0049] S5. Use slicing software to slice the printed mattress model to obtain a processing file, add the mattress raw material to the 3D printer and import the processing file for printing to obtain a 3D printed mattress based on the three-dimensional data.

[0050] In this implementation, the body data is processed by reconstructing triangulated surfaces, closing model holes, and smoothing the model. Details not relevant to mattress customization, such as fingers, toes, and facial features, are removed to create a simplified human body model. This is because large human body model data volumes are detrimental to subsequent simulations. The resulting simplified human body model contains only one-tenth the original data.

[0051] Specific implementation plan 2: Combined Figures 2 to 4 As shown, the S2 includes the following steps:

[0052] S21. Reconstruct and optimize the obtained body shape data to obtain a human body model. Without changing the outline and spinal curve of the human body model, hide some detailed features to obtain a simplified human body model.

[0053] S22, importing the obtained simplified human body model into simulation software, and setting parameters for mass, center of gravity distribution, and human body surface hardness;

[0054] S23. The simplified human body model is meshed. Based on the user's sleeping habits, the simplified human body model is adjusted to different sleeping positions. Boundary conditions are applied to obtain human body simulation models for different sleeping positions. Each obtained human body simulation model is submitted to a solver for solving. Pressure data for the human-bed interface at each sleeping position is obtained, and a human-bed interface pressure map is generated. This embodiment is otherwise identical to the first embodiment.

[0055] Specific implementation plan three: Figure 5 As shown, the method for determining the human body surface hardness in S22 is: fitting the human body surface hardness and the human body BMI value to obtain a fitting curve, calculating the human body BMI value based on the user's body shape data, and substituting the BMI value into the fitting curve to solve for the human body surface hardness value. This embodiment is otherwise the same as the second specific embodiment.

[0056] Specific implementation scheme 4: The simulation software used in S22 is Comsol simulation software. Other aspects of this implementation scheme are the same as those of specific implementation scheme 3.

[0057] Specific implementation scheme 5: The data processing software used in S3 is Origin software. Other aspects of this implementation scheme are the same as those of specific implementation scheme 4.

[0058] Specific implementation plan six: Figure 7 and Figure 8 As shown, the lattice structure in S4 includes a plurality of lattice structure units, each of which is a regular dodecahedron structure unit connected to each other by connecting beams, and the nodes of each regular dodecahedron structure unit are connected by connecting beams. The rest of this embodiment is the same as the specific embodiment five.

[0059] In this embodiment, first construct Figure 6 The mattress base is shown, and then a lattice structure is constructed on the basis of the mattress base. When constructing the lattice structure unit, the regular dodecahedron structure unit is first constructed, and then each node is expanded outward to connect the adjacent structure beams. Each lattice structure unit contains 64 connection points and 74 connection beams. By connecting the lattice structure units, the mattress lattice structure is obtained.

[0060] Specific Implementation Plan 7: As described in S4, the lattice structure of the corresponding area is adjusted based on the combined pressure data to adjust the support and flexibility of the corresponding area. The specific implementation process is as follows: using the maximum pressure value in the combined pressure distribution map as the upper limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is reduced; using the minimum pressure value as the lower limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is increased. The diameter of the connecting beam of the lattice unit structure in the remaining areas is adjusted based on the comparison of the pressure value with the maximum pressure value and the minimum pressure value. This implementation plan is otherwise the same as Specific Implementation Plan 6.

[0061] In this implementation, the regions corresponding to maximum and minimum pressure are first determined, and the ratio of the diameter adjustment of the lattice unit beams between these two regions is determined. The remaining regions are then adjusted based on the pressure values ​​compared to the maximum and minimum pressure values. The diameter of the beams in the regions corresponding to maximum pressure is reduced by 40-60%, while the diameter of the beams in the regions corresponding to minimum pressure is increased by 40-60%. Based on the determined diameter adjustment values ​​for each region, the diameter of the beams in the lattice unit beams is continuously adjusted along the long side of the mattress to adjust the support and softness of each region.

[0062] This implementation scheme optimizes the pressure concentration area to alleviate the discomfort caused by pressure concentration; the optimized and adjusted mattress can disperse the pressure of the user's buttocks and back in contact with the mattress, while providing good support for the waist.

[0063] Specific embodiment eight: The non-contact 3D scanner described in S1 is a line structured light 3D scanner. Other aspects of this embodiment are the same as those of specific embodiment seven.

[0064] Specific embodiment nine: The non-contact three-dimensional scanner in S1 is a laser scanner. Other aspects of this embodiment are the same as those of specific embodiment seven.

[0065] Specific embodiment 10: The non-contact 3D scanner described in S1 is a photographic scanner. Other aspects of this embodiment are the same as those of specific embodiment 7.

[0066] Specific embodiment 11: The non-contact 3D scanner described in S1 is a white light scanner. The rest of this embodiment is the same as specific embodiment 7.

[0067] Specific implementation scheme 12: The slicing software used in S5 is CURA slicing software. The rest of this implementation scheme is the same as specific implementation scheme 8.

[0068] Specific implementation scheme 13: The slicing software used in S5 is magics slicing software. The rest of this implementation scheme is the same as specific implementation scheme 8.

[0069] Specific implementation scheme 14: The slicing software used in S5 is Netfabb slicing software. The rest of this implementation scheme is the same as Specific implementation scheme 8.

[0070] Specific implementation scheme 15: The slicing software used in S5 is Simplify3D slicing software. Other aspects of this implementation scheme are the same as those of Specific implementation scheme 8.

[0071] Specific embodiment 16: The raw material used to construct the lattice structure is silica gel. The rest of this embodiment is the same as the specific embodiment 12.

[0072] Specific embodiment 17: The raw material used to construct the lattice structure is latex. The rest of this embodiment is the same as the specific embodiment 12.

[0073] Specific embodiment 18: The raw material used to construct the lattice structure is polyurethane. The rest of this embodiment is the same as the specific embodiment 12.

[0074] Specific embodiment 19: The raw material used to construct the lattice structure is polyurethane acrylic resin. The rest of this embodiment is the same as the specific embodiment 12.

[0075] Specific embodiment 20: The raw material used to construct the lattice structure is tetraphenylethylene. Other aspects of this embodiment are the same as those of the specific embodiment 12.

[0076] Specific embodiment 21: The raw material used to construct the lattice structure is nylon elastomer. Other aspects of this embodiment are the same as those of the specific embodiment 12.

[0077] Although the present invention is disclosed as above, the scope of protection disclosed by the present invention is not limited thereto. Those skilled in the art of the present invention may make various changes and modifications without departing from the spirit and scope of the present invention, and these changes and modifications will fall within the scope of protection of the present invention.

Claims

1. A mattress manufacturing method based on 3D scanning and 3D printing, characterized in that The steps include: S1. Scanning the user's body with a non-contact 3D scanner to obtain the user's body shape data, including body contour data, body proportion data, body volume data, and center of gravity distribution, and collecting the user's mass and sleeping posture data; S2. Reconstruct, optimize, and simplify the obtained body shape data to obtain a simplified human body model. Import the simplified human body model into simulation software, assign parameters and mesh the simplified human body model, adjust the simplified human body model to different sleeping positions according to the user's sleeping habits, and apply boundary conditions to obtain human body simulation models for different sleeping positions. Calculate the pressure data of the human-bed interface for each sleeping position and generate a pressure distribution map of the human-bed interface. S3. Using data processing software, superimpose the pressure data of the bed interface of each sleeping position, take the maximum pressure value of the overlapping parts of the human body, obtain combined pressure data and generate a combined pressure distribution map; S4. Construct a mattress model with a lattice structure, superimpose the obtained combined pressure distribution map with the lattice structure mattress model, and adjust the lattice structure of the corresponding area according to the combined pressure data to change the support and softness of the corresponding area to obtain a printed mattress model; S5. Slice the printed mattress model using slicing software to obtain a processing file, add the mattress raw material to the 3D printer and import the processing file for printing to obtain a 3D printed mattress based on the three-dimensional data; S2 includes the following steps: S21. Reconstruct and optimize the obtained body shape data to obtain a human body model. Without changing the outline and spinal curve of the human body model, hide some detailed features to obtain a simplified human body model. S22, importing the obtained simplified human body model into simulation software, and setting parameters for mass, center of gravity distribution, and human body surface hardness; S23. Meshing the simplified human body model. Adjusting the simplified human body model to different sleeping positions according to the user's sleeping habits. Applying boundary conditions to obtain human body simulation models for different sleeping positions. Submitting the obtained simulation models for each sleeping position to a solver for solving. Obtaining pressure data for the human-bed interface for each sleeping position and generating a human-bed interface pressure map. The method for determining the human body surface hardness in S22 is: fitting the human body surface hardness and the human body BMI value to obtain a fitting curve, calculating the human body BMI value according to the user's body shape data, and substituting the BMI value into the fitting curve to solve the human body surface hardness value; The lattice structure in S4 includes a plurality of lattice structure units, each of which is a regular dodecahedron structure unit connected to each other by connecting beams, and the nodes of each regular dodecahedron structure unit are connected by connecting beams; As described in S4, the lattice structure of the corresponding area is adjusted according to the combined pressure data to change the support and softness of the corresponding area. The specific implementation process is: with the maximum pressure value in the combined pressure distribution map as the upper limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is reduced; the minimum pressure value is the lower limit, the diameter of the connecting beam of the lattice structure unit in the corresponding area is increased, and the lattice unit structure of the remaining areas adjusts the connecting beam diameter according to the comparison between the pressure value and the maximum pressure value and the minimum pressure value; wherein the diameter of the connecting beam in the area corresponding to the maximum pressure value is reduced by 40-60%, and the diameter of the connecting beam in the area corresponding to the minimum pressure value is increased by 40-60%.

2. A mattress manufacturing method based on 3D scanning and 3D printing according to claim 1, characterized in that The simulation software used in S22 is comsol simulation software.

3. A mattress manufacturing method based on 3D scanning and 3D printing according to claim 2, characterized in that The data processing software used in S3 is Origin software.

4. A mattress manufacturing method based on 3D scanning and 3D printing according to claim 3, characterized in that The non-contact three-dimensional scanner described in S1 is one of a line structured light three-dimensional scanner, a laser scanner, a photographic scanner, and a white light scanner.

5. The mattress manufacturing method based on 3D scanning and 3D printing according to claim 4, characterized in that The slicing software used in the S5 is one of CURA, magics, netfabb, and simplify3D slicing software.

6. The mattress manufacturing method based on 3D scanning and 3D printing according to claim 5, characterized in that The raw materials used to construct the lattice structure are one of silicone, latex, polyurethane, polyurethane acrylic resin, tetraphenylethylene, and nylon elastomer.

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