Rapid manufacturing method of medium-sized figure sculpture pattern

Abstract

The invention discloses a rapid manufacturing method of a medium-sized figure sculpture pattern, and relates to the technical field of sculpture manufacturing. According to the method, a three-dimensional initial model is generated by adopting multi-modal input, parameterization constraint and AI self-iteration, and the problem of proportion imbalance of AI modeling is solved; a three-dimensional standard model is optimized through layering carving, traditional stroke mapping and physical simulation, digital carving and handwork art texture are achieved, a partitioning scheme is designed in a unified mode, and through matching of mechanical positioning, elastic buffering and data association interfaces, the partitioning machining and splicing precision is ensured; and the overall manufacturing is completed through CNC carving, composite gypsum rollover, 3D printing and AR splicing subsequently. According to the method, the problems of low manufacturing efficiency, detail loss, insufficient artistic texture and poor assembly precision in the prior art are solved, the manufacturing period is shortened by 60% or above, the detail reduction degree is larger than or equal to 98%, the model compressive strength is improved by 87%, the assembly error is smaller than or equal to 0.08 mm, and the method is suitable for manufacturing various figure sculptures with the requirements for the artistic effect and the production efficiency.

Description

Technical Field

[0001] This invention relates to the field of sculpture production technology, specifically to a rapid prototyping technology for medium-sized human figure sculptures measuring 3-5 meters, which is particularly suitable for the production of human figure sculptures with high requirements for detail expression, production efficiency and artistic quality. Background Technology

[0002] In the traditional production of medium-sized figure sculptures, there are three main technical approaches, all of which have significant drawbacks: (1) 1:1 Clay Model Direct Sculpting + Plaster Casting Process: This process requires the direct production of a clay model the same size as the finished product. The clay model is huge, making it difficult to shape the clay during the sculpting process. Furthermore, the clay is prone to cracking and deformation during the drying process, requiring repeated repairs. When casting the plaster model, a large amount of plaster material is required, and the casting cycle can take 7-10 days. The entire process is time-consuming and labor-intensive, resulting in extremely low production efficiency. At the same time, the transportation and storage of large-sized clay models require a lot of space, further increasing the production cost.

[0003] (2) Scaled-down clay model sculpting + enlargement process: In order to avoid the defects of 1:1 clay model, some processes use scaled-down clay models of about 1 meter to make, and then enlarge them to generate 1:1 models. However, in this scheme, the size of key parts such as the head and hands after scaling down is only 1 / 3 to 1 / 5 of the original size. Fine structures such as facial expressions (such as eye socket depth and mouth corner curvature) and hand details (such as fingerprints and joint wrinkles) are difficult to depict with traditional clay sculpting tools. Moreover, there is a problem of proportional accuracy decay during the enlargement process. The detail error of the scaled-down model will be enlarged at the same time, resulting in insufficient detail expression of the final 1:1 model, which cannot meet the requirements of artistic creation.

[0004] (3) CNC foam carving + plaster coating process: For artistic elements such as decorative lines on the surface of sculptures, existing technologies mostly adopt the method of CNC processing foam and then directly coating with plaster to smooth it; however, the surface roughness of foam is relatively high, the bonding force between plaster and foam is weak, and the coating is prone to peeling and sanding after coating; moreover, direct plaster coating will blur the outline of CNC processed decorative lines, resulting in a lack of three-dimensionality and artistic tension in the lines, and failing to achieve the expected artistic expression effect.

[0005] The core reason for the above defects is that traditional crafts have not achieved effective synergy between digital technology and traditional clay sculpting techniques. They either rely on pure hand clay sculpting, resulting in low efficiency and poor precision, or rely on single digital processing, resulting in insufficient artistic quality. At the same time, the material selection and process adaptability are poor, and the material performance has not been optimized for the structural characteristics of the sculpture. Summary of the Invention

[0006] This invention solves the problems of existing technologies by combining the artistic expressiveness of traditional clay sculpture with the high precision and efficiency advantages of modern digital technology through an integrated innovative solution of "multimodal AI modeling + layered digital carving + structure-art dual-drive block division + subsequent process collaboration".

[0007] The present invention solves the above-mentioned technical problems through the following technical solution, and the present invention includes the following steps: (1) Designers draw multi-view graphic design drafts according to creative needs, and simultaneously organize style reference drawings and size constraint lists; (2) Using a multimodal constraint-type AI modeling system, import the planar design draft, style reference image, and size constraint list, input natural language prompts, and preset the head-to-body ratio, joint angle, texture density, and surface curvature change rate constraint parameters through the parametric plugin. After 2-3 rounds of AI self-iterative optimization, a three-dimensional initial model is generated. (3) A layered mapping digital carving scheme is adopted, including first-level large structure calibration, second-level medium-scale detail carving, and third-level micro-scale detail carving. During the second-level carving, the traditional clay sculpting brush pressure data is imported to simulate the handmade texture. During the third-level carving, the human body micro-detail library is called and manually corrected. At the same time, the natural shape of clothing folds is simulated through physical simulation. Finally, a three-dimensional standard model with surface roughness Ra≤1μm and detail reproduction ≥98% is obtained. (4) Based on the dual-drive principle of structural mechanics and artistic integrity, the three-dimensional standard model is divided into main modules and detail modules. The main modules are planned and divided according to the self-weight ≤50kg and no processing dead corners. The detail modules are the head and hand blocks. The block interface adopts the structure of "conical positioning pin + annular groove + elastic resin buffer layer". The block management plug-in realizes the association and synchronous update of block data and three-dimensional standard model. (5) Use EPS foam to perform 1:1 CNC engraving on the main module to obtain the main foam model; (6) The main foam model is molded using composite gypsum material to obtain the main gypsum model. The composite gypsum material is made by mixing gypsum powder, glass fiber and water in a mass ratio of 100:5:35. (7) The surface of the main plaster model is smoothed and the decorative details are hand-carved; (8) A 30cm clay model of the head and hands was sculpted and scanned with a laser scanner to obtain three-dimensional data of the head and hands; (9) Import the head and hand 3D data into Geomagic Studio software, perform co-calibration with the 3D standard model, and generate a 1:1 head and hand 3D model; (10) A 1:1 solid model of the head and hands was made by SLA type 3D printing using gradient hardness photosensitive resin. The hardness of the facial area of ​​the gradient hardness photosensitive resin is Shore A 85-90 degrees, and the hardness of the hand area is Shore A 75-80 degrees. (11) Use portable AR glasses to preview the assembly of the 1:1 physical model of the head and hands and the plaster model of the main body. After adjusting the position accuracy to ≤0.08mm, fix and assemble them with stainless steel pins and epoxy resin AB glue to obtain the complete appearance of the medium-sized figure sculpture.

[0008] Furthermore, the resolution of the planar design draft mentioned in step (1) is ≥300dpi, and it includes a front view, a side view, and a top view.

[0009] Furthermore, the multimodal constraint AI modeling system mentioned in step (2) is a combination of Midjourney V5, Blender 3.6 and a self-developed parametric plugin. The parametric constraint parameters include a head-to-body ratio of 1:7-1:8, joint movement angle ≤30°, texture density ≥5 lines / cm², and surface curvature change rate ≤0.5mm / mm.

[0010] Furthermore, the layered mapping digital carving in step (3) uses a combination of ZBrush 2023, Marvelous Designer 12 and pressure-sensing clay sculpting tools. The physical simulation parameters are gravity acceleration of 9.8 N / kg and elastic modulus of the fabric of 200 MPa.

[0011] Furthermore, in step (4), the diameter of the tapered positioning pin is 8mm and the taper is 1:50, and the thickness of the elastic resin buffer layer is 0.5mm and the Shore hardness is A 50 degrees.

[0012] Furthermore, the density of the EPS foam in step (5) is 30 kg / m³, the positioning accuracy of the CNC engraving is ±0.05 mm, and the engraving speed is 500 mm / min.

[0013] Furthermore, the scanning accuracy of the laser scanner in step (8) is ±0.02mm, and the clay material of the head and hand clay model is made by mixing kaolin and bentonite in a mass ratio of 7:3.

[0014] Furthermore, the 3D printing layer thickness in step (10) is 0.05 mm, and the printing accuracy is ±0.03 mm.

[0015] Furthermore, the positioning accuracy of the portable AR glasses in step (11) is ±0.1mm, and the curing time of the epoxy resin AB glue is 30min at 25℃. Beneficial effects

[0016] Compared with the prior art, the present invention has the following significant advantages: (1) Production efficiency increased by more than 60%: By using "multimodal constraint AI modeling", the amount of manual correction work is reduced by 50%. Combined with digital technologies such as CNC carving and 3D printing, the overall production cycle is shortened from the traditional 30-45 days to 10-15 days. (2) Excellent in both detail and artistic quality: 30cm small clay model of head and hands + high-precision scanning + 3D printing, detail reproduction ≥98%; digital carving integrates traditional brush stroke mapping and physical simulation, so that the model has both digital precision and handmade artistic texture, far exceeding the existing technology; (3) The strength and stability of the model are significantly improved: the compressive strength of the composite gypsum material is increased from 15MPa of traditional gypsum to 28MPa. The elastic buffer layer at the block interface absorbs the assembly stress, preventing cracking and falling off, and the overall stability is improved by 100%. (4) The assembly accuracy reaches the industry-leading level: Through "data association block + mechanical positioning + AR collaboration", the assembly error is ≤0.08mm, ensuring the overall proportion of the sculpture is coordinated and no extensive subsequent repairs are required; (5) High flexibility and repeatability: 3D data can be permanently stored, supporting repeated production of the same sculpture; modular design with data synchronization update function allows for flexible adjustment of local structure to adapt to different creative needs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the process of this invention. Detailed Implementation

[0018] The embodiments of the present invention are described in detail below. These embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments.

[0019] like Figure 1 As shown in the figure, this embodiment discloses a rapid method for creating a medium-sized human figure sculpture, which specifically includes the following steps: 1. Materials Clay: 70 parts kaolin, 30 parts bentonite (by weight), add water and stir until the moisture content is 40-45% (it can be formed into a ball by hand without falling apart); Foam material: EPS foam board (density 30kg / m³), with a 10cm processing allowance based on the maximum size of the main module; Composite gypsum material: building-grade gypsum powder (whiteness ≥95%), chopped glass fiber (length 3-5mm), deionized water; Photosensitive resin: Gradient hardness photocurable resin (manufacturer: a 3D printing materials company, model: GR-01); Adhesive material: Epoxy resin AB glue (mixing ratio 1:1, curing time 30 min at 25℃); Elastic resin: Shore A 50 polyurethane elastic resin (thickness 0.5mm); Locating pin: Stainless steel tapered locating pin (diameter 8mm, taper 1:50, length 30mm).

[0020] 2. Equipment Graphics equipment: High-performance computer, with Photoshop 2023 and CorelDRAW 2022 installed; AI modeling equipment: high-performance computer, equipped with Midjourney V5, Blender 3.6, and self-developed parametric plugins; Model adjustment equipment: High-performance computer, with ZBrush 2023, Marvelous Designer 12, Geomagic Studio 2022, and Keyshot 10 installed; Data acquisition equipment: pressure-sensing clay sculpting tool, 3D laser scanner; CNC engraving equipment: Gantry CNC engraving machine; 3D printing equipment: SLA stereolithography 3D printer; AR devices: Portable AR glasses; Auxiliary tools: 400-800 grit sandpaper, clay sculpting tool set, level, laser rangefinder.

[0021] 3. Specific operating steps (1) Graphic design: Based on the theme, the designer draws the front view, side view and top view, organizes style reference drawings, formulates a list of size constraints, and saves them in PNG + Excel format; (2) Generation of the initial 3D model: ① Multimodal input: Open the self-developed parametric plugin, import the planar design draft and style reference image, and input natural language prompts; ② Parametric constraint settings: Set the core parameters through the plugin and click "Constraints Take Effect"; ③ AI self-iterative optimization: Start the iteration, generate 3 candidate models in the first round, and the designer marks the optimization points; in the second round, the AI ​​adjusts based on the annotations, generates the optimized model, verifies the core dimensions, and meets the constraint requirements; ④ Initial model inspection: Use the Blender measurement tool to check the joint angles and texture density. After confirming that there are no out-of-tolerance errors, export it as a high-precision STL format (triangular mesh density of 1.8 million faces); (3) Fine adjustment of the three-dimensional standard model (layered mapping digital sculpting): ① Level 1 sculpting (macrostructure calibration): Import the STL file into ZBrush 2023, adjust the central axis of the torso, optimize the shoulder and neck connection curvature, and ensure the parallelism of the limbs is 0.15mm / m; ② Level 2 sculpting (medium-scale details): Connect the pressure sensor clay sculpting tool (sampling frequency 100Hz), collect the brush pressure data of the sculptor's hand sculpting (pressure range 0.5-2.0N), import it into ZBrush and map it to the sculpting brush, and sculpt according to the rule of "light stroke at the beginning - heavy stroke in the middle - light stroke at the end"; ③ Level 3 sculpting (micro-scale details): Call the human micro-detail library, import the skin texture (pore diameter 0.1mm, spacing 0.3mm) and nail texture (line width 0.08mm), use the Alpha brush to fit the model surface, and manually correct the details of the eyes and lips (eye fissure length 2.5cm, lip thickness 3mm); ④ Physical simulation correction: Import the model into Marvelous Designer 12. Set the fabric parameters to simulate the natural drooping of the skirt under gravity, generate dynamic fabric data, and synchronize it to ZBrush to update the model; ⑤ Global coordination verification: Perform warm light rendering in Keyshot, check the continuity of surface curvature, confirm the distinct layers, and export the final 3D standard model (STL format, triangular mesh density of 2.2 million faces). (4) Model block processing (structural-art dual-drive modular block): ① Block planning: Start the self-developed block management plugin in Geomagic Studio 2022 and plan the blocks according to the principle of "structural mechanics + artistic integrity": Main modules: anterior chest trunk block, posterior back trunk block, upper arm-forearm left / right block, thigh-lower leg left / right block; Detail modules: head block, left hand block, right hand block; the boundaries of the blocks are set along the bottom of the skirt folds and the non-visual area on the side of the torso, avoiding the face and the complete scroll pattern band on the chest; ② Interface Design: Generate a “tapered locating pin + annular groove” interface using a plugin. The locating pin has a diameter of 8mm and a taper of 1:50. The annular groove has a width of 10mm and a depth of 5mm. Add a 0.5mm thick elastic resin layer (Shore A 50 degrees) to the interface contact surface. Export the STL file of each block and the interface parameter table (including locating pin coordinates and interface flatness requirements). ③ Data association and binding: Bind the block data to the 3D standard model and set the "synchronous update" function. If the standard model size is modified later, the interface parameters and size data of each block will be automatically corrected to avoid deviation. ④ Feasibility verification: Import the segmented STL file into AutoCAD 2024 to simulate the CNC carving path, plaster mold casting and demolding angle, and 3D printing support layout, and confirm the feasibility of the segmentation scheme; (5) CNC machining of the main module: Import the block STL file of the main module into the CNC engraving machine control system, call the machining parameters in the block management plug-in, fix the EPS foam board, start the engraving, clean up the foam debris after completion, and obtain the main foam model; (6) Plaster casting of the main module: Mix plaster powder: glass fiber: water = 100:5:35 in proportion, stir evenly (stirring time 5min, no bubbles), and apply evenly to the surface of the main foam model (thickness 15-20mm). Cure at room temperature (22℃) for 24h. After the plaster has completely cured, remove the foam base layer to obtain the main plaster model. (7) Fine carving of the main model: Use 400 grit sandpaper to polish the surface of the main plaster model (polish until Ra≤2μm), and then use clay sculpting tools to manually carve the details of the scroll pattern to ensure smooth lines and consistent depth (error≤±0.3mm). (8) Head and Hand Model Making and Scanning: Use the prepared clay to sculpt a 30cm high head model and a 25cm long hand model, and finely carve the facial features and fingerprints; use a laser scanner to scan the model and generate three-dimensional head and hand data (STL format). (9) Head and hand data collaborative calibration: Import the head and hand 3D data into Geomagic Studio 2022, perform position calibration with the main module 3D model, adjust the connection angle between the head and hand and the torso, control the calibration error within ±0.1mm, and generate a 1:1 head and hand 3D model; (10) Head and Hand Model 3D Printing: Import the 1:1 three-dimensional model of the head and hands into the 3D printer, select the gradient hardness photosensitive resin, set the printing parameters (layer thickness 0.05mm, exposure time 8s / layer), and start printing; after printing, remove the support, no additional mold repair is required (surface Ra≤1μm). (11) AR Preview Assembly: Wear AR glasses, import the interface positioning pin coordinate data, place the head and hand model at the splicing point of the main model, and use AR superimposed positioning marks and mechanical positioning pins to coordinate positioning. Adjust the position deviation to ≤0.08mm, fix the splicing interface with stainless steel pins, and then apply epoxy resin AB glue for reinforcement. Curing at room temperature for 30 minutes completes the overall assembly.

[0022] 4. Finished product inspection After assembly, a laser rangefinder is used to check the overall size (error ≤ ±5mm), and a high-precision camera is used to photograph the details to confirm that the facial expressions, hand textures, and decorative lines meet the design requirements. The model is considered a qualified finished product if there are no cracks or detachments and no obvious gaps at the joints.

[0023] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0024] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0025] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A rapid method for creating the appearance of a medium-sized human figure sculpture, characterized in that, Includes the following steps: (1) Designers draw multi-view graphic design drafts according to creative needs, and simultaneously organize style reference drawings and size constraint lists; (2) Using a multimodal constraint-type AI modeling system, import the planar design draft, style reference image, and size constraint list, input natural language prompts, and preset the head-to-body ratio, joint angle, texture density, and surface curvature change rate constraint parameters through the parametric plugin. After 2-3 rounds of AI self-iterative optimization, a three-dimensional initial model is generated. (3) A layered mapping digital carving scheme is adopted, including first-level large structure calibration, second-level medium-scale detail carving, and third-level micro-scale detail carving. During the second-level carving, the traditional clay sculpting brush pressure data is imported to simulate the handmade texture. During the third-level carving, the human body micro-detail library is called and manually corrected. At the same time, the natural shape of clothing folds is simulated through physical simulation. Finally, a three-dimensional standard model with surface roughness Ra≤1μm and detail reproduction ≥98% is obtained. (4) Based on the dual-drive principle of structural mechanics and artistic integrity, the three-dimensional standard model is divided into main modules and detail modules. The main modules are planned and divided according to the self-weight ≤50kg and no processing dead corners. The detail modules are the head and hand blocks. The block interface adopts the structure of "conical positioning pin + annular groove + elastic resin buffer layer". The block management plug-in realizes the association binding and synchronous update of block data with the three-dimensional standard model. (5) Use EPS foam to perform 1:1 CNC engraving on the main module to obtain the main foam model; (6) The main foam model is molded using composite gypsum material to obtain the main gypsum model. The composite gypsum material is made by mixing gypsum powder, glass fiber and water in a mass ratio of 100:5:

35. (7) The surface of the main plaster model is smoothed and the decorative details are hand-carved; (8) A 30cm clay model of the head and hands was sculpted and scanned with a laser scanner to obtain three-dimensional data of the head and hands; (9) Import the head and hand 3D data into Geomagic Studio software, perform co-calibration with the 3D standard model, and generate a 1:1 head and hand 3D model; (10) A 1:1 solid model of the head and hands was made by SLA type 3D printing using gradient hardness photosensitive resin. The hardness of the facial area of ​​the gradient hardness photosensitive resin is Shore A 85-90 degrees, and the hardness of the hand area is Shore A 75-80 degrees. (11) Use portable AR glasses to preview the assembly of the 1:1 physical model of the head and hands and the plaster model of the main body. After adjusting the position accuracy to ≤0.08mm, fix and assemble them with stainless steel pins and epoxy resin AB glue to obtain the complete appearance of the medium-sized figure sculpture.

2. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The resolution of the 2D design draft mentioned in step (1) is ≥300dpi, and it includes the front view, side view and top view.

3. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The multimodal constraint AI modeling system mentioned in step (2) is a combination of Midjourney V5, Blender 3.6 and self-developed parametric plugins. The parametric constraint parameters include head-to-body ratio of 1:7-1:8, joint movement angle ≤30°, texture density ≥5 lines / cm², and surface curvature change rate ≤0.5mm / mm.

4. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The layered mapping digital sculpting in step (3) uses a combination of ZBrush 2023, Marvelous Designer 12 and pressure-sensing clay sculpting tools. The physical simulation parameters are gravity acceleration of 9.8 N / kg and elastic modulus of fabric of 200 MPa.

5. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The conical positioning pin in step (4) has a diameter of 8 mm and a taper of 1:

50. The elastic resin buffer layer has a thickness of 0.5 mm and a Shore hardness of A 50.

6. The method for rapidly producing a medium-sized human figure sculpture according to claim 1, characterized in that: The EPS foam in step (5) has a density of 30 kg / m³, the CNC engraving has a positioning accuracy of ±0.05 mm, and the engraving speed is 500 mm / min.

7. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The scanning accuracy of the laser scanner mentioned in step (8) is ±0.02mm, and the clay material of the head and hand clay model is made by mixing kaolin and bentonite in a mass ratio of 7:

3.

8. The method for rapidly producing a medium-sized human figure sculpture according to claim 1, characterized in that: The 3D printing layer thickness in step (10) is 0.05 mm, and the printing accuracy is ±0.03 mm.

9. The rapid production method for a medium-sized human figure sculpture according to claim 1, characterized in that: The positioning accuracy of the portable AR glasses in step (11) is ±0.1mm, and the curing time of the epoxy resin AB glue is 30min at 25℃.

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