Intelligent stone mold making device and method based on three-dimensional scanning and multi-level technology

Abstract

The present invention belongs to, but is not limited to, the field of molding production technology, and discloses an intelligent stone mold maker and method based on three-dimensional scanning and multi-level processes. Through automated and intelligent design, it integrates multifunctional operating units such as material batching, mixing, injection molding, curing, polishing, coloring, and quality inspection. The entire manufacturing process is highly automated and precisely controlled, and can quickly and efficiently produce simulated moldings that are similar in appearance, hardness, and specific gravity to real rocks and fossils, suitable for display needs in museum exhibitions and educational venues. The intelligent stone mold maker integrates advanced automation and intelligent control systems through efficient raw material delivery, mixing, injection molding, curing, polishing, and coloring processes, and can quickly produce highly simulated rock and fossil molded products. The intelligent detection system ensures the quality of the finished product, and the waste recycling mechanism achieves environmentally friendly manufacturing.

Description

Technical Field

[0001] The present invention belongs to but is not limited to the field of molding production technology, and in particular relates to an intelligent stone molding maker and method based on three-dimensional scanning and multi-level technology. Background Art

[0002] Molding technology can be traced back to ancient civilizations, when people began using simple molds and plastic materials to create various tools and objects. Over time, molding technology has continued to develop and improve, gradually forming a variety of different crafts and production methods. In modern industrial production, molding technology has become a key forming process, widely used in various fields such as automobiles, home appliances, electronics, and medical devices. At the same time, handmade molding technology, due to its unique artistry and personalized characteristics, has also gained widespread application in fields such as art and toy making. The basic principle of molding is to inject a heated, softened or fluid material into a mold and then solidify and shape the material inside the mold by applying pressure and temperature. However, traditional manual molding processes are subject to human error and instability.

[0003] Through the above analysis, the problems and defects of the existing technology are as follows:

[0004] Human errors and instability problems exist in the traditional manual production process. Summary of the Invention

[0005] In view of the problems existing in the prior art, the present invention provides an intelligent stone mold manufacturing device and method based on three-dimensional scanning and multi-level technology.

[0006] The present invention is achieved by a method for manufacturing intelligent stone molds based on three-dimensional scanning and multi-level technology, comprising the following steps:

[0007] Step 1: Automatic batching and delivery of raw materials

[0008] An intelligent control system dispatches the automatic batching unit for raw materials according to preset molding formula instructions. Sensors monitor the remaining material levels in different storage bins, and the automatic batching unit accurately delivers raw materials such as resin, cement, sand powder, and additives into the conveying channel according to the proportion, and then transports them to the mixing unit. This process ensures the precise proportions of different materials and the consistency of the quality of the mixture.

[0009] Step 2: Mixing and Adjustment

[0010] After the mixing unit receives the ingredients, multiple agitators perform mixing operations according to the parameters set by the control system; the stirring speed and time are adjusted by the intelligent control system according to the requirements of different materials to ensure that the raw materials are mixed evenly and form a mixture with different physical properties; this step provides the basic material for molding, with high fluidity and plasticity, for subsequent injection molding.

[0011] Step 3: Mold injection and molding

[0012] The mixed material is injected into the mold's injection unit through an automatic injection system; a robotic arm evenly distributes the material within the mold based on its size and shape, and applies appropriate pressure and vibration to eliminate bubbles, ensuring the density and detail of the molding. This step ensures that the appearance, hardness, and texture simulation of the finished molded product are consistent with real rocks and fossils.

[0013] Step 4: Curing and preliminary shaping

[0014] After injection molding is completed, the mold enters the curing unit, where the temperature and humidity are adjusted through the temperature control system to control the curing time and ensure that the molding material hardens in a stable environment. During this process, the system automatically adjusts the temperature curve according to the characteristics of the material (such as resin or cement). After curing, the intelligent carving arm performs preliminary carving and shaping on the surface to make the appearance of the mold closer to the real rock or fossil shape.

[0015] Step 5: Polishing and coloring

[0016] After the mold is cured, it enters the polishing unit. Based on the set smoothness and surface treatment requirements, the system automatically selects the appropriate grinding wheel and gradually fine-polishes the surface to ensure smoothness and refine details. After polishing, the mold moves to the painting unit, where a robot applies a preset color scheme and spray coating technology to precisely color the mold, creating a realistic visual effect that is indistinguishable from real rocks and fossils.

[0017] Step 6: Quality Inspection and Adjustment

[0018] The quality inspection unit uses laser scanners and image recognition technology to inspect moldings. By identifying problems such as bubbles, cracks, surface unevenness, and whether the color conforms to the preset scheme, the system automatically makes adjustments or returns to the finishing step to ensure that the molding meets high quality standards.

[0019] Step 7: Intelligent Management and Control

[0020] The entire process is coordinated and managed by a central intelligent control system. Users can set the recipe, morphology design and processing requirements through the interface; the system records the data of each manufacturing process and supports remote control and operation to facilitate batch production or process optimization; the system can also make real-time adjustments based on actual production conditions to ensure efficient operation.

[0021] Step 8: Waste recycling and environmental protection treatment

[0022] Waste and residues generated during the manufacturing process are processed through a waste recovery unit, which separates recyclable materials and reintroduces them into the manufacturing process, reducing waste and complying with environmental protection requirements.

[0023] Furthermore, the molding method comprises the following steps:

[0024] Step 1: Material selection and preparation

[0025] 1.1 Select representative rocks and fossils as the original model, ensuring the structural integrity and details of the model;

[0026] 1.2 Prepare various stone element samples to replicate the texture and color of the original model and ensure the natural effect of the finished product;

[0027] 1.3 Prepare a variety of resin materials suitable for molding, including high-strength resin and transparent resin, for the expression of different textures;

[0028] Step 2: Molding process

[0029] 2.1 Use a high-precision 3D scanner to perform three-dimensional scanning of the original rock or fossil to obtain an accurate digital model to ensure the accuracy of mold making

[0030] 2.2 Based on the 3D scanning data, use customized mold equipment to make a negative mold that matches the original model;

[0031] 2.3 Apply release agent evenly inside the female mold to ensure that the mold is easy to disassemble;

[0032] 2.4 Mix the resin material with the selected stone element sample in proportion and pour it into the negative mold to ensure that the material fully fills the mold and avoids the generation of bubbles and gaps;

[0033] Step 3: Shaping and Strengthening

[0034] 3.1 Before the resin material hardens, shape the model in the mold to ensure the realism and accuracy of the details;

[0035] 3.2 Add reinforcement materials, such as fiber mesh or reinforcing agents, to further enhance the structural strength and prevent the model from cracking or deformation;

[0036] 3.3 After the resin material solidifies, remove the model from the negative mold and check the integrity of the model;

[0037] Step 4: Polishing and painting

[0038] 4.1 Perform preliminary polishing on the demoulding model to remove excess surface material and ensure a smooth surface;

[0039] 4.2 Use fine sandpaper to further polish to improve the fineness and realism of the model surface;

[0040] 4.3 Hand-painted according to the color of the original rock or fossil, using pigments or dyes for multi-layered color processing to achieve a simulated effect;

[0041] Step 5: Post-molding and processing

[0042] 5.1 Oxidation treatment: Apply an oxidant to the surface of the model to simulate the oxidation effect during natural weathering, so that the model presents a naturally aged texture;

[0043] 5.2 Injection technology: Use high-precision tools to inject patterns on the surface of the model to imitate the natural texture and fine cracks of rocks or fossils, making the model more realistic;

[0044] 5.3 Glaze treatment: After the oxidation and injection process is completed, the model is treated with transparent glaze to further protect the model surface and improve the gloss and durability.

[0045] Furthermore, the shaping and reinforcement:

[0046] After the resin material solidifies, demould and take out the preliminary model;

[0047] Use cement, sand powder and other additives of different specifications to strengthen and shape the model;

[0048] If needed, support structures or fillers can be added to the model.

[0049] Furthermore, the polishing and coloring:

[0050] Fine sanding of the model to remove surface blemishes and uneven parts;

[0051] Use professional painting techniques to paint the model and restore the color and texture of the original rock or fossil;

[0052] During the coloring process, multi-layer painting and gradient techniques can be used.

[0053] Furthermore, the three-dimensional scanning accuracy in step 2.1 is 0.01 mm to 0.05 mm, ensuring that the scanned digital model can capture the tiny texture details of the original rock or fossil, thereby improving the accuracy of the mold and the simulation effect of the final product.

[0054] The mixing ratio of the resin material and the stone elements in step 2.4 is adjusted according to the texture and color of the original model, wherein the amount of stone elements added is 10% to 40%, and the proportion of the resin material is 60% to 90%, to ensure that the hardness and simulated texture of the finished model match the original model.

[0055] Furthermore, the reinforcement materials used in step 3.2 include carbon fiber mesh, glass fiber or nano-reinforcement agent. By evenly distributing these reinforcement materials in the resin material, the overall structural strength of the model can be increased by 30% to 50%, thereby preventing the model from deformation or cracking during long-term display or use.

[0056] Furthermore, the coloring process in step 4.3 uses a multi-layer spraying process, first spraying the base color, then coloring the texture of the middle layer, and finally adjusting the details. The pigment used is a weather-resistant pigment to ensure that the color of the model is not easy to fade or deteriorate during long-term display.

[0057] Furthermore, the oxidation treatment in step 5.1 uses an oxidant and a humidity and temperature control system that simulates the natural environment. The oxidation treatment lasts for 2 to 8 hours at an ambient temperature of 20°C to 40°C to simulate the oxidation effect of real rocks or fossils under natural weathering conditions, so that the surface of the model presents a natural aged texture and feel.

[0058] Furthermore, the glaze treatment in step 5.3 uses UV-curable transparent resin, the glaze thickness is 0.1mm to 0.3mm, and the glaze is cured by light during the glaze process to ensure the transparency and durability of the glaze layer, so that the model maintains high gloss and wear resistance during long-term use.

[0059] Another object of the present invention is to provide an intelligent stone mold manufacturing device based on an intelligent stone mold manufacturing method of three-dimensional scanning and multi-level technology, comprising:

[0060] Automatic raw material batching unit: It consists of multiple raw material storage bins, each storing different types of resin materials, cement, sand powder, and various additives. Sensors monitor the remaining amount of raw materials and automatically adjust the proportions of different materials according to the formula. The batching unit is connected to the central intelligent control system to control the precise delivery of materials.

[0061] Mixing unit: Multiple agitators and automatic mixing devices are used to mix the different materials fed into the batching unit according to the required proportions. The agitators adjust the mixing speed and time as needed to ensure uniform mixing of resin, cement, sand powder, and additives, and can produce various material combinations according to different molding requirements. The entire mixing process is monitored by a central intelligent control system.

[0062] Mold injection unit: Equipped with multiple mold trays, it is used to inject the mixed material into the mold. The injection unit's robotic arm automatically injects the material, ensuring that the material is evenly distributed within the mold. Pressure and vibration are used to remove air bubbles, enhancing the density and detail of the molded part. The robotic arm can adapt to molds of different sizes and shapes, providing high flexibility.

[0063] Curing and shaping unit: After injection molding is completed, the mold enters the curing unit for temperature control. This unit is equipped with a heating system and a cooling system to control the curing temperature and time, ensuring a stable and uniform hardening process for the mold. It also uses intelligent temperature and humidity sensors to automatically adjust the environmental conditions according to the curing requirements of different materials.

[0064] In addition, after curing, the intelligent engraving arm can be used for preliminary shaping, engraving and fine-tuning the mold surface details to form a preliminary molding form;

[0065] Polishing and coloring unit: After curing and shaping, the mold enters the polishing unit, which is equipped with an automatic polishing device. According to the set smoothness requirements, the mold surface is polished step by step to remove uneven surfaces and add details. Grinding wheels of different grit sizes can be automatically switched according to needs.

[0066] After polishing, the mold will enter the coloring unit, where the coloring robot arm will color the mold surface through automatic spraying or brushing technology according to the pre-set color scheme;

[0067] Quality Inspection and Adjustment Unit: At each stage of molding, the system is equipped with high-precision laser scanners and image recognition technology to perform quality inspections. The inspection unit identifies defects, bubbles, or cracks on the molded surface, and determines whether the color meets preset requirements, and automatically adjusts the system based on the inspection results.

[0068] Intelligent control system: The entire manufacturing machine is managed by a central intelligent control system, which integrates automatic batching, injection molding, curing, polishing, coloring, and testing functions. The system supports parameterized customization, allowing users to set specific requirements such as molding material formula, shape design, and surface treatment through the interface. The system also supports remote operation and data logging, allowing users to easily perform multiple manufacturing operations, record parameters, and optimize processes.

[0069] Waste recycling and environmental protection unit: used to recycle waste and residues from the manufacturing process; the waste is processed and then re-enters the manufacturing process.

[0070] In combination with the above technical solutions and the technical problems solved, the advantages and positive effects of the technical solutions to be protected by the present invention are as follows:

[0071] First, through the molding method, rock and fossil models with realistic appearance, specific gravity, hardness and shape can be produced to meet the needs of exhibition displays.

[0072] The design of the intelligent stone mold maker realizes the mechanization and intelligence of the production process, improves production efficiency and reduces labor costs.

[0073] The quality and stability of the model are guaranteed by the precise material adding, mixing and molding system.

[0074] The problems of human error and instability existing in the traditional manual production process have been effectively solved.

[0075] It solves the problem of wear and tear of fossil and rock specimens caused by human and natural factors during exhibition.

[0076] Through the application of intelligent manufacturers, the demand for efficient and mass production of rock and fossil models in exhibition venues has been realized.

[0077] Second, the technical solution of the present invention solves the following technical problems in the prior art in industrial applications and achieves significant technical progress:

[0078] 1) Technical problems of existing technologies

[0079] (1) Insufficient mold accuracy and detail restoration:

[0080] Traditional molding processes rely on hand carving and low-precision molds, which cannot accurately replicate the subtle textures and shapes of the original model. Especially when replicating the complex texture of rocks or fossils, details are easily lost, affecting the simulation effect of the final product.

[0081] (2) Limited material selection and texture performance:

[0082] Existing technologies are usually relatively simple in material selection, especially the texture and color of stone and fossils are difficult to replicate with traditional materials, resulting in unrealistic simulation effects, and the material strength is not high, and the model is prone to cracking or deformation.

[0083] (3) Lack of multifunctional post-processing technology:

[0084] Traditional molding methods mostly rely on surface polishing and simple coloring processes, which make it difficult to simulate natural aging, oxidation, and weathering effects. They also lack complex post-processing processes such as injection molding and simulated oxidation treatment, resulting in insufficient simulation and poor visual effects of the model.

[0085] 2) Significant technological advancements in technical solutions

[0086] (1) Improve the accuracy and detail restoration of the mold:

[0087] This invention utilizes high-precision 3D scanning technology to precisely capture the three-dimensional form of the original rock or fossil. Combined with customized mold-making techniques, this technology ensures that every detail is perfectly rendered during the final molding process. This significantly improves the accuracy and detail of the model, especially when dealing with complex shapes and subtle textures.

[0088] (2) Provide diverse material options to enhance texture performance:

[0089] This invention combines various stone elements with high-performance resin materials to accurately simulate the realistic texture and color of different rocks or fossils. By mixing stone powder, mineral particles, and resin materials in appropriate proportions, the resulting model not only possesses visual realism but also improves its mechanical properties, significantly enhancing its strength and durability and avoiding the cracking problem of traditional models.

[0090] (3) Introducing post-oxidation and graining treatment to improve simulation effects:

[0091] The present invention incorporates complex post-molding processing, including oxidation and graining. These steps simulate the long-term weathering and oxidation of rocks or fossils in natural environments, imparting realistic aging and cracking effects to the model's surface. Compared to traditional polishing and coloring, this post-processing imparts a more historical and natural feel to the model, further enhancing the simulation.

[0092] (4) Improve production efficiency and adaptability:

[0093] The 3D scanning and customized mold technology employed in this invention simplify and streamline repetitive operations during model production. Through digital production methods, high-precision models can be rapidly reproduced in batches, addressing the inefficiency and high cost of traditional manual production. This method is particularly well-suited for large-scale application in areas such as cultural relic restoration and museum displays, significantly improving the effectiveness of industrial applications.

[0094] 3) The actual application effect of technological progress

[0095] In industrial applications, especially in museum exhibitions, cultural relic restoration, scientific research and teaching, this invention provides a highly realistic, durable model production solution with complex textures and textures, which makes up for the shortcomings of existing technologies. Its technical advantages are:

[0096] Improved model simulation: Through precise 3D scanning and post-processing, the model surface exhibits texture and feel very similar to the original object, solving the problem of poor detail performance in existing technologies.

[0097] Improved material properties: The combination of resin material and stone elements not only gives the model a realistic appearance, but also improves its mechanical properties, making it more durable during long-term display or use.

[0098] Strong process scalability: The process flow of the present invention is highly flexible and scalable, can adapt to the production needs of models of different sizes and materials, and can be quickly mass-produced, with high industrial value.

[0099] In summary, the present invention has achieved significant technological progress by solving the problems of insufficient mold precision, limited material performance and imperfect post-processing in the prior art, and has strong practical application value and promotion potential. BRIEF DESCRIPTION OF THE DRAWINGS

[0100] Figure 1 This is a flow chart of an intelligent stone mold manufacturing method based on three-dimensional scanning and multi-level technology provided by an embodiment of the present invention;

[0101] Figure 2 This is a structural diagram of an intelligent stone mold maker based on three-dimensional scanning and multi-level technology provided by an embodiment of the present invention;

[0102] In the figure: 1. Automatic raw material batching unit; 11. Raw material storage bin; 12. Sensor; 2. Mixing unit; 21. Agitator; 22. Automatic mixing device; 3. Mold injection unit; 31. Mold tray; 32. Robotic arm; 4. Curing and shaping unit; 41. Heating system; 42. Cooling system; 43. Temperature and humidity sensor; 44. Engraving arm; 5. Polishing and coloring unit; 51. Grinding wheel; 52. Coloring robot arm; 6. Quality inspection and adjustment unit; 61. Laser scanner; 7. Intelligent control system; 8. Waste recycling and environmental protection unit. DETAILED DESCRIPTION

[0103] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0104] like Figure 1 As shown, an embodiment of the present invention provides an intelligent stone mold manufacturing method based on three-dimensional scanning and multi-level technology, comprising the following steps:

[0105] Step 1: Automatic batching and delivery of raw materials

[0106] An intelligent control system dispatches the automatic batching unit for raw materials according to preset molding formula instructions. Sensors monitor the remaining material levels in different storage bins, and the automatic batching unit accurately delivers raw materials such as resin, cement, sand powder, and additives into the conveying channel according to the proportion, and then transports them to the mixing unit. This process ensures the precise proportions of different materials and the consistency of the quality of the mixture.

[0107] Step 2: Mixing and Adjustment

[0108] After the mixing unit receives the ingredients, multiple agitators perform mixing operations according to the parameters set by the control system; the stirring speed and time are adjusted by the intelligent control system according to the requirements of different materials to ensure that the raw materials are mixed evenly and form a mixture with different physical properties; this step provides the basic material for molding, with high fluidity and plasticity, for subsequent injection molding.

[0109] Step 3: Mold injection and molding

[0110] The mixed material is injected into the mold's injection unit through an automatic injection system; a robotic arm evenly distributes the material within the mold based on its size and shape, and applies appropriate pressure and vibration to eliminate bubbles, ensuring the density and detail of the molding. This step ensures that the appearance, hardness, and texture simulation of the finished molded product are consistent with real rocks and fossils.

[0111] Step 4: Curing and preliminary shaping

[0112] After injection molding is completed, the mold enters the curing unit, where the temperature and humidity are adjusted through the temperature control system to control the curing time and ensure that the molding material hardens in a stable environment. During this process, the system automatically adjusts the temperature curve according to the characteristics of the material (such as resin or cement). After curing, the intelligent carving arm performs preliminary carving and shaping on the surface to make the appearance of the mold closer to the real rock or fossil shape.

[0113] Step 5: Polishing and coloring

[0114] After the mold is cured, it enters the polishing unit. Based on the set smoothness and surface treatment requirements, the system automatically selects the appropriate grinding wheel and gradually fine-polishes the surface to ensure smoothness and refine details. After polishing, the mold moves to the painting unit, where a robot applies a preset color scheme and spray coating technology to precisely color the mold, creating a realistic visual effect that is indistinguishable from real rocks and fossils.

[0115] Step 6: Quality Inspection and Adjustment

[0116] The quality inspection unit uses laser scanners and image recognition technology to inspect moldings. By identifying problems such as bubbles, cracks, surface unevenness, and whether the color conforms to the preset scheme, the system automatically makes adjustments or returns to the finishing step to ensure that the molding meets high quality standards.

[0117] Step 7: Intelligent Management and Control

[0118] The entire process is coordinated and managed by a central intelligent control system. Users can set the recipe, morphology design and processing requirements through the interface; the system records the data of each manufacturing process and supports remote control and operation to facilitate batch production or process optimization; the system can also make real-time adjustments based on actual production conditions to ensure efficient operation.

[0119] Step 8: Waste recycling and environmental protection treatment

[0120] Waste and residues generated during the manufacturing process are processed through a waste recovery unit, which separates recyclable materials and reintroduces them into the manufacturing process, reducing waste and complying with environmental protection requirements.

[0121] like Figure 2 As shown, an embodiment of the present invention provides an intelligent stone mold manufacturing device based on a three-dimensional scanning and multi-level process intelligent stone mold manufacturing method, comprising:

[0122] Automatic raw material batching unit 1: It consists of multiple raw material storage bins 11, which store different types of resin materials, cement, sand powder and various additives respectively; the remaining amount of raw materials is monitored by sensors 12, and the system can automatically adjust the proportions of different materials according to the formula; the batching unit is connected to the central control system to control the precise delivery of materials.

[0123] Mixing unit 2: Multiple agitators 21 and automatic mixing devices 22 are used to mix the different materials fed into the batching unit according to the proportions. The agitators can adjust the stirring speed and time as needed to ensure uniform mixing of resin, cement, sand powder and additives, and can generate various material combinations according to different molding requirements. The entire mixing process is monitored by an intelligent control system.

[0124] Mold Injection Unit 3: Equipped with multiple mold trays 31, this unit is specifically designed to inject the mixed material into the mold. The unit's robotic arm 32 automatically injects material, ensuring even distribution within the mold. Pressure and vibration are used to remove air bubbles, enhancing the density and detail of the molded part. The robotic arm can accommodate molds of varying sizes and shapes, providing a high degree of flexibility.

[0125] Curing and Shaping Unit 4: After injection molding, the mold enters the curing unit for temperature control. This unit is equipped with a heating system 41 and a cooling system 42 to control the curing temperature and time, ensuring a stable and uniform hardening process. This stage utilizes an intelligent temperature and humidity sensor 43 to automatically adjust environmental conditions based on the curing requirements of different materials.

[0126] In addition, after solidification, the intelligent engraving arm 44 can be used for preliminary shaping, and the surface details of the mold can be engraved and fine-tuned to form a preliminary molded shape.

[0127] Polishing and Coloring Unit 5: After curing and shaping, the mold enters the polishing unit, which is equipped with an automatic polishing device. It can gradually polish the molded surface according to the set smoothness requirements, remove surface irregularities and add details. Different grit grinding wheels 51 can be automatically switched according to demand.

[0128] After polishing, the mold will enter the coloring unit, and the coloring robot arm 53 will color the surface of the mold through automatic spraying or brushing technology according to the pre-set color scheme, making its appearance more realistic with real rocks and fossils.

[0129] Quality Inspection and Adjustment Unit 6: At each stage of the molding process, the system is equipped with a high-precision laser scanner 61 and image recognition technology to perform quality inspections. The inspection unit can identify defects, bubbles, or cracks on the molded surface, determine whether the color meets preset requirements, and automatically adjust the process based on the inspection results.

[0130] Intelligent Control System 7: The entire manufacturing machine is managed by a central intelligent control system, integrating functions such as automatic batching, injection molding, curing, polishing, coloring, and testing. The system supports parametric customization, allowing users to set specific requirements such as molding material formula, shape design, and surface treatment through the interface. The system also supports remote operation and data logging, facilitating multiple manufacturing runs, parameter recording, and process optimization.

[0131] Waste Recycling and Environmental Protection Unit 8: Recycles waste and residues from the manufacturing process. After processing, the waste can be re-entered into the manufacturing process, reducing waste and meeting environmental protection requirements.

[0132] The intelligent stone mold maker integrates multifunctional operating units such as material batching, mixing, injection molding, curing, polishing, coloring, and quality inspection through automated and intelligent design. The entire manufacturing process is highly automated and precisely controlled, and can quickly and efficiently produce simulated molds with appearance, hardness, and specific gravity similar to real rocks and fossils. They are suitable for display needs in museum exhibitions and educational venues.

[0133] The intelligent stone mold maker integrates advanced automation and intelligent control systems through efficient raw material conveying, mixing, injection molding, curing, polishing, and coloring processes, enabling rapid production of highly realistic rock and fossil molded products. An intelligent inspection system ensures the quality of the finished product, while a waste recycling mechanism ensures environmentally friendly manufacturing.

[0134] The working principle of the intelligent stone mold maker relies on the coordination of the intelligent control system and the automated operation of each unit to ensure that the entire manufacturing process is efficient and accurate.

[0135] Specific technical solution for implementing the present invention

[0136] 1. Refinement of molding production process:

[0137] Material selection and preparation:

[0138] Select representative rocks and fossils as original models.

[0139] Prepare samples of various stone elements to replicate the texture and color of the original model.

[0140] Prepare a variety of resin materials to ensure the stability and durability of the model.

[0141] Molding process:

[0142] Use a high-precision 3D scanner to scan the original rock or fossil in three dimensions to obtain an accurate digital model.

[0143] Based on the scan data, a custom mold is used to create a negative mold that matches the original model.

[0144] Apply a release agent to the inside of the female mold to facilitate subsequent demoulding.

[0145] Mix the resin material with the chosen stone element and pour it into the negative mold, making sure the material fills the mold thoroughly.

[0146] Shaping and strengthening:

[0147] After the resin material solidifies, the preliminary model is removed from the mold.

[0148] The model is reinforced and shaped using cement, sand powder and other additives of different specifications to enhance its structural stability and durability.

[0149] If necessary, support structures or fillers can be added to the model to increase the model's load-bearing capacity and impact resistance.

[0150] Polishing and painting:

[0151] Finely sand the model to remove surface blemishes and uneven parts, making the model surface smooth and detailed.

[0152] Paint your models using professional painting techniques to reproduce the colors and textures of the original rock or fossil.

[0153] During the coloring process, multi-layer painting and gradient techniques can be used to make the colors more natural and realistic.

[0154] 2. Intelligent stone mold maker design:

[0155] Integration of mechanization and intelligence:

[0156] Design an intelligent mechanical tool that integrates molding, shaping, and post-processing.

[0157] The tool should have functions such as automatic mixing, adding, and molding to reduce manual operations and improve production efficiency.

[0158] An intelligent control system is introduced to achieve automatic adjustment and monitoring of parameters such as material proportion, temperature, and humidity.

[0159] Material adding and mixing system:

[0160] Design an automated material addition system that can accurately add resin, cement, sand powder and other materials according to preset proportions.

[0161] Adopting efficient mixing device to ensure that the materials are fully mixed and uniform in a short time.

[0162] Forming and processing systems:

[0163] Design an adjustable mold system to accommodate rock or fossil models of varying sizes and shapes.

[0164] Equipped with high-precision polishing and coloring equipment to achieve automated fine processing of models.

[0165] The molding manufacturing method comprises the following steps:

[0166] Step 1: Material selection and preparation

[0167] 1.1 Select representative rocks and fossils as the original model, ensuring the structural integrity and details of the model;

[0168] 1.2 Prepare various stone element samples to replicate the texture and color of the original model and ensure the natural effect of the finished product;

[0169] 1.3 Prepare a variety of resin materials suitable for molding, including high-strength resin and transparent resin, for the expression of different textures;

[0170] Step 2: Molding process

[0171] 2.1 Use a high-precision 3D scanner to perform three-dimensional scanning of the original rock or fossil to obtain an accurate digital model to ensure the accuracy of mold making

[0172] 2.2 Based on the 3D scanning data, use customized mold equipment to make a negative mold that matches the original model;

[0173] 2.3 Apply release agent evenly inside the female mold to ensure that the mold is easy to disassemble;

[0174] 2.4 Mix the resin material with the selected stone element sample in proportion and pour it into the negative mold to ensure that the material fully fills the mold and avoids the generation of bubbles and gaps;

[0175] Step 3: Shaping and Strengthening

[0176] 3.1 Before the resin material hardens, shape the model in the mold to ensure the realism and accuracy of the details;

[0177] 3.2 Add reinforcement materials, such as fiber mesh or reinforcing agents, to further enhance the structural strength and prevent the model from cracking or deformation;

[0178] 3.3 After the resin material solidifies, remove the model from the negative mold and check the integrity of the model;

[0179] Step 4: Polishing and painting

[0180] 4.1 Perform preliminary polishing on the demoulding model to remove excess surface material and ensure a smooth surface;

[0181] 4.2 Use fine sandpaper to further polish to improve the fineness and realism of the model surface;

[0182] 4.3 Hand-painted according to the color of the original rock or fossil, using pigments or dyes for multi-layered color processing to achieve a simulated effect;

[0183] Step 5: Post-molding and processing

[0184] 5.1 Oxidation treatment: Apply an oxidant to the surface of the model to simulate the oxidation effect during natural weathering, so that the model presents a naturally aged texture;

[0185] 5.2 Injection technology: Use high-precision tools to inject patterns on the surface of the model to imitate the natural texture and fine cracks of rocks or fossils, making the model more realistic;

[0186] 5.3 Glaze treatment: After completing the oxidation and injection processes, the model is treated with transparent glaze to further protect the model surface and improve the gloss and durability.

[0187] Furthermore, the shaping and reinforcement:

[0188] After the resin material is solidified, the preliminary model is removed from the mold;

[0189] Use cement, sand powder and other additives of different specifications to strengthen and shape the model;

[0190] If necessary, support structures or fillers can be added to the model.

[0191] Furthermore, the polishing and coloring:

[0192] Fine sanding of the model to remove surface blemishes and uneven parts;

[0193] Use professional painting techniques to paint the model and restore the color and texture of the original rock or fossil;

[0194] During the coloring process, multi-layer painting and gradient techniques can be used.

[0195] Furthermore, the three-dimensional scanning accuracy in step 2.1 is 0.01 mm to 0.05 mm, ensuring that the scanned digital model can capture the tiny texture details of the original rock or fossil, thereby improving the accuracy of the mold and the simulation effect of the final product.

[0196] The mixing ratio of the resin material and the stone elements in step 2.4 is adjusted according to the texture and color of the original model, wherein the amount of stone elements added is 10% to 40%, and the proportion of the resin material is 60% to 90%, to ensure that the hardness and simulated texture of the finished model match the original model.

[0197] Furthermore, the reinforcement materials used in step 3.2 include carbon fiber mesh, glass fiber or nano-reinforcement agent. By evenly distributing these reinforcement materials in the resin material, the overall structural strength of the model can be increased by 30% to 50%, thereby preventing the model from deformation or cracking during long-term display or use.

[0198] Furthermore, the coloring process in step 4.3 uses a multi-layer spraying process, first spraying the base color, then coloring the texture of the middle layer, and finally adjusting the details. The pigment used is a weather-resistant pigment to ensure that the color of the model is not easy to fade or deteriorate during long-term display.

[0199] Furthermore, the oxidation treatment in step 5.1 uses an oxidant and a humidity and temperature control system that simulates the natural environment. The oxidation treatment lasts for 2 to 8 hours at an ambient temperature of 20°C to 40°C to simulate the oxidation effect of real rocks or fossils under natural weathering conditions, so that the surface of the model presents a natural aged texture and feel.

[0200] Furthermore, the glaze treatment in step 5.3 uses UV-curable transparent resin, the glaze thickness is 0.1mm to 0.3mm, and the glaze is cured by light during the glaze process to ensure the transparency and durability of the glaze layer, so that the model maintains high gloss and wear resistance during long-term use.

[0201] The following are four specific molding method embodiments:

[0202] Example 1: Molding of a rock texture simulation model

[0203] 1) Material selection and preparation:

[0204] Choose a typical volcanic rock as the original model. Prepare stone elements with a rough texture, such as volcanic ash and finely crushed basalt grains; use transparent resin and high-strength resin as the base material.

[0205] 2)Molding process:

[0206] A 3D scanner was used to scan the volcanic rock in three dimensions, creating a highly accurate digital model. A custom silicone mold was used to create a negative mold, and a release agent was applied to the mold. A transparent resin and volcanic ash mixture was then poured into the mold, ensuring that every detail was fully filled.

[0207] 3) Shaping and reinforcement:

[0208] The rough surface texture of the volcanic rock was hand-sculpted before the resin hardened. A fiber mesh was used to reinforce the model's structural strength and prevent cracking during the curing process.

[0209] 4) Polishing and coloring:

[0210] The solidified model is meticulously sanded and then painted with multiple layers of gray, black, and crimson pigments to simulate the true color of volcanic rock. Finally, it is oxidized to enhance the weathering effect of the rock.

[0211] Example 2: Molding of a fossil replica model

[0212] 1) Material selection and preparation:

[0213] Choose a piece of limestone containing fish fossils as the original model. Prepare stone powder and high-viscosity resin material with a texture similar to that of limestone.

[0214] 2)Molding process:

[0215] A 3D scanner was used to precisely capture the details of the fish fossil. Based on the scanned data, a negative mold was created that matched the original fossil, and a release agent was applied to the mold. A mixture of stone powder and resin was poured into the mold, ensuring that the minute details of the fossil were perfectly reproduced.

[0216] 3) Shaping and reinforcement:

[0217] Before the resin hardens, the surface structure of the fossil is carefully sculpted, especially the texture of the bones. A carbon fiber mesh is added for reinforcement to ensure the long-term stability of the model.

[0218] 4) Polishing and coloring:

[0219] Fine-grit sandpaper was used to polish the model to highlight the fossil's texture. Light gray, white, and brown were used for coloring, and oxidation was used to simulate the fossil's natural aging. Finally, tiny cracks and textures were injected to enhance the realistic effect.

[0220] Example 3: Molding of a cave stalactite simulation model

[0221] 1) Material selection and preparation:

[0222] Select a section of stalactite as a model, prepare fine stone powder and translucent resin material to imitate the crystal texture of the stalactite.

[0223] 2)Molding process:

[0224] The stalactites were 3D scanned to capture their shape and surface crystal details. The scanned data was used to create a custom negative mold, which was then coated with a release agent. A mixture of stone powder and resin was poured into the mold, ensuring the stalactite's texture and structure were fully reproduced.

[0225] 3) Shaping and reinforcement:

[0226] Initial shaping of the resin is done to preserve the stalactite's natural, hanging form. Fiber reinforcement is added to ensure the model does not break at larger sizes.

[0227] 4) Polishing and coloring:

[0228] The model was finely polished using polishing tools to enhance the smoothness of its crystal surface. White, transparent, and light blue pigments were used to simulate the natural colors of stalactites. A photocatalytic oxidation process was added to enhance the model's texture.

[0229] Example 4: Molding of a Simulated Model of a Dinosaur Footprint Fossil

[0230] 1) Material selection and preparation:

[0231] A dinosaur footprint fossil was selected as the original model, and coarse-grained sand and wear-resistant resin materials were prepared to imitate the rough surface of the footprint fossil.

[0232] 2)Molding process:

[0233] A 3D scan of the dinosaur footprint fossils is performed to accurately capture the footprint's shape. A negative mold is created based on the scanned data, and a release agent is applied to the mold. A mixture of coarse sand and resin is poured into the negative mold to ensure a complete reproduction of the footprint's shape.

[0234] 3) Shaping and reinforcement:

[0235] Use tools to finely carve the edges of the footprints to maintain their realism. Use reinforcement materials such as fiberglass mesh to strengthen the model and prevent it from wear and tear during long-term display.

[0236] 4) Polishing and coloring:

[0237] The footprints were lightly sanded to preserve their roughness. They were then painted using tan and gray pigments to simulate soil and fossil surfaces. Finally, fine cracks and artificial weathering were added to further enhance the model's realism.

[0238] These four examples demonstrate the simulation production process of different types of rocks, fossils, and stalactites. Each step reflects the details of material selection, molding process, and post-processing to ensure that the model has a highly realistic effect.

[0239] The above description is only a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with this technical field within the technical scope disclosed by the present invention and within the spirit and principles of the present invention should be covered by the scope of protection of the present invention.

Claims

1. An intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology, characterized by comprising the following steps: Step 1: Automatic batching and delivery of raw materials The intelligent control system dispatches the automatic batching unit for raw materials according to the preset molding formula instructions. Sensors monitor the remaining material levels in different storage bins, and the automatic batching unit accurately distributes the resin, cement, sand powder and additives in proportion to the conveying channel and then transports them to the mixing unit. Step 2: Mixing and Adjustment After the mixing unit receives the ingredients, multiple agitators perform mixing operations according to the parameters set by the control system. The mixing speed and time are adjusted by the intelligent control system according to the requirements of different materials to ensure that the raw materials are mixed evenly and form a mixture with different physical properties. Step 3: Mold injection and molding The mixed material is injected into the injection unit of the mold through an automatic injection system; the robotic arm evenly distributes the material in the mold according to the size and shape of the mold, and removes bubbles by applying appropriate pressure and vibration to ensure the density and detail of the mold; Step 4: Curing and preliminary shaping After injection molding is completed, the mold enters the curing unit, where the temperature and humidity are adjusted by the temperature control system to control the curing time and ensure that the molding material hardens in a stable environment. During the curing process, the system automatically adjusts the temperature curve according to the characteristics of the material. After curing, the intelligent carving arm performs preliminary carving and shaping on the surface, making the appearance of the mold more similar to the shape of real rock or fossil. Step 5: Polishing and coloring After the molding is cured, it enters the polishing unit. Based on the set smoothness and surface treatment requirements, the appropriate grinding wheel is automatically selected to gradually perform fine polishing on the surface to ensure surface flatness and modify details. After polishing, the mold is moved to the painting unit, where the robot arm accurately paints the mold using a preset color scheme and spraying technology. Step 6: Quality Inspection and Adjustment The quality inspection unit uses laser scanners and image recognition technology to inspect moldings. By identifying bubbles, cracks, surface unevenness, and whether the color conforms to the preset plan, it automatically makes adjustments or returns to the finishing step to ensure that the molding meets high quality standards. Step 7: Intelligent Management and Control The entire process is coordinated and managed by a central intelligent control system, where users can set recipes, form designs, and processing requirements through an interface. The system records data from each manufacturing process and supports remote control and operation, facilitating batch production or process optimization. The system also makes real-time adjustments based on actual production conditions to ensure efficient operation. Step 8: Waste recycling and environmental protection treatment Waste and residues generated during the manufacturing process are processed through a waste recovery unit; recyclable materials are separated and re-entered into the manufacturing process; The molding method comprises the following steps: Step 1: Material selection and preparation 1.1 Select representative rocks and fossils as the original model, ensuring the structural integrity and details of the model; 1.2 Prepare various stone element samples to replicate the texture and color of the original model and ensure the natural effect of the finished product; 1.3 Prepare a variety of resin materials suitable for molding, including high-strength resin and transparent resin, for the expression of different textures; Step 2: Molding process 2.1 Use a high-precision 3D scanner to perform three-dimensional scanning of the original rock or fossil to obtain an accurate digital model to ensure the accuracy of mold making 2.2 Based on the 3D scanning data, use customized mold equipment to make a negative mold that matches the original model; 2.3 Apply release agent evenly inside the female mold to ensure that the mold is easy to disassemble; 2.4 Mix the resin material with the selected stone element sample in proportion and pour it into the negative mold to ensure that the material fully fills the mold and avoids the generation of bubbles and gaps; Step 3: Shaping and Strengthening 3.1 Before the resin material hardens, shape the model in the mold to ensure the realism and accuracy of the details; 3.2 Add reinforcement materials, such as fiber mesh or reinforcing agents, to further enhance the structural strength and prevent the model from cracking or deformation; 3.3 After the resin material solidifies, remove the model from the negative mold and check the integrity of the model; Step 4: Polishing and painting 4.1 Perform preliminary polishing on the demoulding model to remove excess surface material and ensure a smooth surface; 4.2 Use fine sandpaper to further polish to improve the fineness and realism of the model surface; 4.3 Hand-painted according to the color of the original rock or fossil, using pigments or dyes for multi-layered color processing to achieve a simulated effect; Step 5: Post-molding and processing 5.1 Oxidation treatment: Apply an oxidant to the surface of the model to simulate the oxidation effect during natural weathering, so that the model presents a naturally aged texture; 5.2 Injection technology: Use high-precision tools to inject patterns on the surface of the model to imitate the natural texture and fine cracks of rocks or fossils, making the model more realistic; 5.3 Glaze treatment: After completing the oxidation and injection processes, the model is treated with transparent glaze to further protect the model surface and improve the gloss and durability.

2. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1, characterized in that the shaping and reinforcement: After the resin material is solidified, the preliminary model is removed from the mold; Use cement, sand powder and other additives of different specifications to strengthen and shape the model; Add support structures or fillers to the model as needed.

3. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1 is characterized in that: The polishing and coloring: Fine sanding of the model to remove surface blemishes and uneven parts; Use professional painting techniques to paint the model and restore the color and texture of the original rock or fossil; In the coloring process, multi-layer painting and gradient techniques are used.

4. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1 is characterized in that: The 3D scanning accuracy in step 2.1 is 0.01 mm to 0.05 mm, ensuring that the scanned digital model can capture the minute texture details of the original rock or fossil, thereby improving the accuracy of the mold and the simulation effect of the final product; The mixing ratio of the resin material and the stone elements in step 2.4 is adjusted according to the texture and color of the original model, wherein the amount of stone elements added is 10% to 40%, and the proportion of the resin material is 60% to 90%, to ensure that the hardness and simulated texture of the finished model match the original model.

5. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1 is characterized in that: The reinforcement materials used in step 3.2 include carbon fiber mesh, glass fiber, or nano-reinforcement agents. By evenly distributing these reinforcement materials in the resin material, the overall structural strength of the model can be increased by 30% to 50%, thereby preventing the model from deformation or cracking during long-term display or use.

6. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1 is characterized in that: The coloring process in step 4.3 uses a multi-layer spraying process, first spraying the base color, then coloring the texture of the middle layer, and finally adjusting the details. The pigment used is a weather-resistant pigment to ensure that the color of the model is not easy to fade or deteriorate during long-term display.

7. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology according to claim 1 is characterized in that: The oxidation treatment in step 5.1 uses an oxidant and a humidity and temperature control system that simulates the natural environment. The oxidation treatment lasts for 2 to 8 hours at an ambient temperature of 20°C to 40°C to simulate the oxidation effect of real rocks or fossils under natural weathering conditions, so that the model surface presents a natural aged texture and feel.

8. The intelligent stone molding manufacturing method based on three-dimensional scanning and multi-level technology as claimed in claim 1, characterized in that: The glaze treatment in step 5.3 uses UV-curable transparent resin, the glaze thickness is 0.1mm to 0.3mm, and the glaze is cured by light during the glaze process to ensure the transparency and durability of the glaze layer, so that the model maintains high gloss and wear resistance during long-term use.

9. An intelligent stone mold manufacturing device according to any one of claims 1 to 8, characterized in that: include: Automatic raw material batching unit: It consists of multiple raw material storage bins, each storing different types of resin materials, cement, sand powder, and various additives. Sensors monitor the remaining amount of raw materials and automatically adjust the proportions of different materials according to the formula. The batching unit is connected to the central intelligent control system to control the precise delivery of materials. Mixing unit: uses multiple agitators and automatic mixing devices to mix the different materials fed into the batching unit according to the proportion; The agitator adjusts the mixing speed and time as needed to ensure uniform mixing of resin, cement, sand powder and additives, and can produce various material combinations according to different molding requirements; the entire mixing process is monitored by a central intelligent control system; Mold injection unit: Equipped with multiple mold trays, it is used to inject the mixed material into the mold. The injection unit's robotic arm automatically injects the material, ensuring that the material is evenly distributed within the mold. Pressure and vibration are used to remove air bubbles, enhancing the density and detail of the molded part. The robotic arm can adapt to molds of different sizes and shapes, providing high flexibility. Curing and shaping unit: After injection molding is completed, the mold enters the curing unit for temperature control. This unit is equipped with a heating and cooling system to control the curing temperature and time to ensure a stable and uniform hardening process for the mold. It also uses intelligent temperature and humidity sensors to automatically adjust the environmental conditions according to the curing requirements of different materials. In addition, after curing, the intelligent engraving arm can be used for preliminary shaping, engraving and fine-tuning the mold surface details to form a preliminary molding form; Polishing and coloring unit: After curing and shaping, the mold enters the polishing unit, which is equipped with an automatic polishing device. According to the set smoothness requirements, the mold surface is polished step by step to remove uneven surfaces and add details. Grinding wheels of different grit sizes can be automatically switched according to needs. After polishing, the mold will enter the coloring unit, where the coloring robot arm will color the mold surface through automatic spraying or brushing technology according to the pre-set color scheme; Quality inspection and adjustment unit: At each stage of molding manufacturing, the system is equipped with high-precision laser scanners and image recognition technology to perform quality inspection; The inspection unit identifies whether there are defects, bubbles or cracks on the molded surface, whether the color meets the preset requirements, and automatically adjusts according to the inspection results; Intelligent control system: The entire manufacturing machine is managed by a central intelligent control system, which integrates automatic batching, injection molding, curing, polishing, coloring, and testing functions. The system supports parameterized customization, allowing users to set specific requirements for molding material formula, shape design, and surface treatment through the interface. The system also supports remote operation and data logging, allowing users to easily perform multiple manufacturing operations, record parameters, and optimize processes. Waste recycling and environmental protection unit: used to recycle waste and residues from the manufacturing process; the waste is processed and then re-enters the manufacturing process.

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