Image generation control device and optical shaping apparatus

Abstract

To provide an image generation control device and an optical shaping apparatus which can accurately shape a shaped article while enhancing adhesion of each curable layer.SOLUTION: An image generation control device 30 includes: a design image data holding part 31 for holding design image data in which each light irradiation region corresponding to one or a plurality of kinds of photocurable resins 1 is regulated in each layer of a shaped article 2; a boundary detection part 33 for detecting a boundary in which a first photocurable resin 1-1 to be previously shaped and a second photocurable resin 1-2 to be shaped later are brought into contact with each other in the same layer on the basis of the design image data; and an image data correction part 34 for correcting the design image data so that the irradiation region of the second photocurable resin 1-2 is overlapped with the irradiation region of the first photocurable resin 1-1 about the boundary.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an image generation control device and a stereolithography device. [Background technology]

[0002] Generally, stereolithography is known, which irradiates a liquid photocurable resin with light, such as ultraviolet light, to form a three-dimensional object made of cured resin. Patent Document 1 discloses a stereolithography technique in which a desired object is formed by stacking cured layers by repeatedly irradiating a base (platform) facing a light-transmitting window on the bottom of a liquid vat containing the photocurable resin with light corresponding to the cross-sectional shape of the object at a predetermined height, forming a cured layer of cured resin on the underside of the base in the same shape as the predetermined cross-section, and then lifting the base up a predetermined height relative to the liquid vat. Patent Document 2 also discloses a technique for using different photocurable resins and irradiating them with light at different exposure doses in a pattern to join and mold multiple different cured objects. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-62841 [Patent Document 2] Japanese Patent Application Publication No. 09-277384 Summary of the Invention [Problem to be solved by the invention]

[0004] Recently, optical lithography has been explored, in which multiple photocurable resins are placed adjacent to each other in the same layer, forming an object at the same height relative to the base. In this type of configuration, a predetermined irradiation area of ​​one photocurable resin is irradiated with light to harden the first photocurable resin, and then the second photocurable resin is replaced with another photocurable resin. This process is then repeated for each layer. To accurately form an object, it is preferable to increase the adhesion between multiple adjacent photocurable resins in the same layer. However, during actual lithography, the mechanical precision of the base and the precision of the light irradiated to the predetermined irradiation area may result in inadequate adhesion between the multiple photocurable resins. This leaves room for improvement in terms of accurately forming an object.

[0005] The present invention has been made in consideration of the above, and aims to provide an image generation control device and a photo-fabrication device that can improve the adhesion of multiple photo-curable resins within the same layer and accurately form objects. [Means for solving the problem]

[0006] In order to solve the above-mentioned problems and achieve the object, the present invention provides an image generation control device that controls light that is irradiated onto a photocurable resin adjusted to a predetermined thickness, hardening the photocurable resin and forming a model layer by layer, and includes: a design image data storage unit that stores design image data in which, for each layer of the model, an irradiation area of ​​light corresponding to one or more types of photocurable resin is defined; a boundary portion detection unit that detects, based on the design image data, a boundary portion where one photocurable resin that is formed first and another photocurable resin that is formed later come into contact with each other within the same layer; and an image data correction unit that corrects the design image data for the boundary portion so that the irradiation area of ​​the other photocurable resin overlaps with the irradiation area of ​​one photocurable resin.

[0007] The present invention also provides a modeling tank that stores photocurable resin and has a light-transmitting section on its bottom surface; a light irradiation section that irradiates light to harden the photocurable resin through the light-transmitting section; a platform that faces the light-transmitting section and can be raised and lowered relative to the modeling tank; and an image generation control device that controls the light that is irradiated from the light irradiation section onto photocurable resin that has been adjusted to a predetermined thickness, hardening the photocurable resin and forming a model layer by layer.The image generation control device includes: a design image data storage section that stores design image data in which light irradiation areas corresponding to one or more types of photocurable resin are defined for each layer of the model; a boundary portion detection section that detects, based on the design image data, a boundary portion where one photocurable resin to be formed first and another photocurable resin to be formed later come into contact with each other within the same layer; and an image data correction section that corrects the design image data for the boundary portion so that the irradiation area of ​​the other photocurable resin overlaps the irradiation area of ​​one photocurable resin. [Effects of the Invention]

[0008] According to the present invention, it is possible to improve the adhesion of a plurality of photocurable resins in the same layer, thereby enabling a shaped object to be shaped with high precision. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the first embodiment. [Figure 2] FIG. 2 is a flowchart showing the procedure of the operation of the image generation control device. [Figure 3] FIG. 3 is a plan view showing an example of a shaped object showing a boundary portion. [Figure 4] FIG. 4 is a diagram showing a procedure for forming a modeled object. [Figure 5] FIG. 5 is a schematic diagram showing the basic configuration of a photo-fabrication apparatus according to the second embodiment. [Figure 6] FIG. 6 is a flowchart showing the procedure of the operation of the image generation control device. [Figure 7]FIG. 7 is a perspective view showing an example of a shaped object formed by molding one photocurable resin within a region surrounded by a cured layer of the other photocurable resin, as viewed from the bottom. [Figure 8] FIG. 8 is a diagram showing a procedure for forming a modeled object. DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings. Note that the present invention is not limited to these embodiments, and when there are multiple embodiments, the present invention also includes configurations that combine the embodiments. In the following embodiments, the same components are designated by the same reference numerals, and redundant explanations will be omitted.

[0011] In the following description of the embodiments, unless otherwise specified, uncured (uncured) liquid photocurable resin will be simply referred to as photocurable resin. Furthermore, a layer of photocurable resin of a predetermined thickness that is provided between a platform (described below) or a model held on the platform and a light-transmitting plate and that will be cured by light irradiation will be referred to as a photocurable resin layer or simply as a resin layer. Furthermore, a photo-fabricated object formed by curing liquid photocurable resin will be referred to as a three-dimensional object or simply as a model. This three-dimensional object is not limited to a finished product in which all of the multiple cured layers are stacked, but also includes an unfinished product in which only intermediate cured layers have been stacked.

[0012] [First embodiment] 1 is a schematic diagram showing the basic configuration of a stereolithography apparatus according to a first embodiment. As shown in FIG. 1, the stereolithography apparatus 10 includes a plurality of (two in FIG. 1) modeling tanks 11, 11, a platform 12, a light irradiation unit 20, and an image generation control device 30.

[0013] The two modeling tanks 11, 11 are dish-shaped with an open top, and each of the two modeling tanks 11, 11 stores a plurality of different types (two types) of photocurable resin 1. Each of the modeling tanks 11 has a light-transmitting plate (light-transmitting portion) 14 on its bottom surface. This light-transmitting plate 14 transmits light that cures the photocurable resin 1.

[0014] The photocurable resin 1 is a raw material for the three-dimensional object 2. In this embodiment, the photocurable resin 1 includes a first photocurable resin 1-1 (one of the photocurable resins) and a second photocurable resin 1-2 (the other of the photocurable resins). The first photocurable resin 1-1 and the second photocurable resin 1-2 are resin materials that are cured by different types of light (e.g., photocurable flowable resins that are cured by X-rays, ultraviolet light, or visible light). Preferably, the first photocurable resin 1-1 and the second photocurable resin 1-2 each include three elements: an oligomer (e.g., epoxy acrylate, urethane acrylate), a reactive diluent (monomer), and a photopolymerization initiator (e.g., a benzoin-based or acetophenone-based compound). In this embodiment, the first photocurable resin 1-1 has the property of curing at a shorter wavelength than the second photocurable resin 1-2. In this embodiment, when the first photocurable resin 1-1 and the second photocurable resin 1-2 are not distinguished from each other, they are simply referred to as photocurable resin 1.

[0015] The platform 12 holds the object 2 formed from the cured photocurable resin 1 (the first photocurable resin 1-1 and the second photocurable resin 1-2), and is disposed above the modeling tank 11, facing the light-transmitting plate 14. The platform 12 is formed in a polygonal plate shape, such as a circular or rectangular plate, and is disposed so that its lower surface 12A is substantially parallel to the upper surface 14A of the light-transmitting plate 14. The platform 12 is also connected to a platform lifting mechanism 15, and is provided so that it can be raised and lowered relative to the modeling tank 11 by the operation of the platform lifting mechanism 15. Specifically, the platform 12 can move toward and away from the light-transmitting plate 14, and holds the object 2 formed on the lower surface 12A facing the light-transmitting plate 14.

[0016] In this embodiment, the optical modeling apparatus 10 is also provided with a movement mechanism (not shown) that allows the two modeling tanks 11, 11 to be horizontally moved below the platform 12 while the platform 12 is retracted upward. As a result, by disposing the modeling tank 11 storing either the first photocurable resin 1-1 or the second photocurable resin 1-2 below the platform 12, it is possible to switch to the desired photocurable resin 1 and sequentially form the modeled objects 2. Note that, although this embodiment is configured to include two modeling tanks 11, 11 that store two different types of photocurable resins 1, the present invention is not limited to this. For example, a configuration may be adopted in which paths are provided for supplying and recovering each type of photocurable resin 1 so that multiple types of photocurable resins 1 can be switched between and used in one modeling tank 11 as needed.

[0017] The light irradiation unit 20 is disposed, for example, below the modeling tank 11, i.e., on the opposite side of the platform 12 across the light-transmitting plate 14. The light irradiation unit 20 irradiates, for example, light L1 for curing the first photocurable resin 1-1 and light L2 for curing the second photocurable resin 1-2 through the light-transmitting plate 14, in accordance with the predetermined cross-sectional shape of the target object. The irradiated lights L1 and L2 may be any light capable of curing the target first photocurable resin 1-1 and second photocurable resin 1-2, and may be, for example, X-rays, ultraviolet light, or short-wavelength visible light. The light irradiation unit 20 includes a light source 21, an image forming element 22, a reflecting mirror 23, and a projection lens 24.

[0018] The light source 21 emits light L1 and L2 to be irradiated onto the image-forming element 22, and preferably includes, for example, an ultraviolet lamp or a visible light lamp. The image-forming element 22 modulates the light in accordance with data on the cross-sectional shape of each layer of the object 2 to be formed, and may be, for example, an LCOS (Liquid Crystal On Silicon) device, a Digital Mirror Device (DMD), or a liquid crystal device. In this embodiment, the image-forming element 22 can modulate light in different irradiation areas for each type of photocurable resin 1 in the above-mentioned cross-sectional shape under the control of the image generation control device 30.

[0019] The reflecting mirror 23 reflects the light modulated by the image forming element 22 toward the projection lens 24. The projection lens 24 forms an image of the light reflected by the reflecting mirror 23. Note that the light irradiation unit 20 is not limited to this, and may be, for example, a laser scanning device that uses a laser light source and mirror drive, or an optical device that uses a reflective optical system or a refractive optical system.

[0020] In this embodiment, the optical lithography apparatus 10 performs optical lithography by placing multiple photocurable resins 1 (first photocurable resin 1-1 and second photocurable resin 1-2) adjacent to each other in the same layer of the object 2 to be formed at the same height relative to the platform 12. Specifically, as shown in FIG. 1 , the optical lithography apparatus 10 forms a photocurable resin layer of a predetermined thickness t made of, for example, the first photocurable resin 1-1 between the platform 12 or the object 2 and the light-transmitting plate 14, and irradiates this photocurable resin layer with light of a predetermined cross-sectional shape modulated by the image forming element 22. As a result, a cured layer of the first photocurable resin 1-1 having the same shape as the predetermined cross section is formed on the lower surface of the platform 12 or the object 2. Next, the second photocurable resin 1-2 is replaced with the modeling tank 11 in which it is stored, and a photocurable resin layer of the second photocurable resin 1-2 with a predetermined thickness t is formed at the same height as the cured layer of the first photocurable resin 1-1. Light of a predetermined cross-sectional shape modulated by the image forming element 22 is irradiated onto this photocurable resin layer. As a result, a cured layer of the second photocurable resin 1-2 is formed adjacent to the cured layer of the first photocurable resin 1-1 and with the same shape as the predetermined cross-section. This predetermined thickness t is set to the thickness of one cured layer to be formed (for example, several μm to approximately 100 μm). While the first photocurable resin 1-1 and the second photocurable resin 1-2 are replaced, the platform 12 is raised a distance equal to the predetermined thickness t, and each photocurable resin layer with the predetermined thickness t is again formed between the platform 12 or the model 2 and the light-transmitting plate 14. In this way, the photopolymerization device 10 repeatedly performs the steps of irradiating light onto a photopolymerization resin layer of a predetermined thickness t while replacing multiple photopolymerization resins 1, and then raising the platform 12 by the predetermined thickness t, thereby stacking the cured layers to form a molded object 2 of the desired shape.

[0021] The image generation control device 30 is an arithmetic processing device configured, for example, with a CPU (Central Processing Unit) and controls the operation of the light irradiation unit 20. The image generation control device 30 stores a program related to the operation of irradiating light onto the photocurable resin 1, loads this program into memory, and executes the instructions contained in the program. The image generation control device 30 includes an internal memory (not shown), which is used for temporary storage of data such as the program in the image generation control device 30.

[0022] The image generation control device 30 calculates a light irradiation pattern that shows the cross-sectional shape of the object at predetermined height intervals based on, for example, the three-dimensional shape data, and controls the image forming element 22 etc. to irradiate the light onto the photocurable resin 1. The image generation control device 30 includes a design image data storage unit 31, a modeling schedule data storage unit 32, a boundary portion detection unit 33, an image data correction unit 34, and a corrected image data storage unit 35.

[0023] The design image data storage unit 31 stores design image data that defines the irradiation areas of light (image light) corresponding to the types of photocurable resin 1 (first photocurable resin 1-1 and second photocurable resin 1-2) in each layer (each cured layer) when forming the target object 2. This irradiation area corresponds to the cross-sectional shape of each layer when each photocurable resin 1 (first photocurable resin 1-1 and second photocurable resin 1-2) is cured. In this embodiment, the design image data includes boundary portions where each photocurable resin 1 (first photocurable resin 1-1 and second photocurable resin 1-2) contacts each other within the same layer. If the target object 2 is formed of k layers (k is a natural number), the design image data storage unit 31 stores design image data that defines the irradiation areas of light (image light) corresponding to each photocurable resin 1 in all layers from layer 1 to layer k.

[0024] The modeling schedule data storage unit 32 stores schedule data indicating the modeling order of the photocurable resin 1 in a predetermined layer of the modeled object 2. That is, the modeling schedule data storage unit 32 stores schedule data that specifies, for each layer, whether the first photocurable resin 1-1 or the second photocurable resin 1-2 should be modeled first. Unless there is a special reason, the modeling schedule data storage unit 32 stores schedule data that specifies, in each layer, that the photocurable resin 1 (first photocurable resin 1-1) that is cured with light having a shorter wavelength is modeled first. With this configuration, light with a shorter wavelength has higher exposure accuracy, and therefore the modeled object 2 can be modeled with high accuracy.

[0025] The boundary portion detection unit 33 detects a boundary portion where the first photocurable resin 1-1 to be molded first and the second photocurable resin 1-2 to be molded later come into contact with each other within the same layer, based on the design image data and the schedule data. This boundary portion refers to a portion where the edge of the first photocurable resin 1-1 comes into contact with the edge of the second photocurable resin 1-2.

[0026] The image data correction unit 34 corrects the design image data for the detected boundary portion so that the irradiation area of ​​the second photocurable resin 1-2 to be modeled later overlaps the irradiation area of ​​the first photocurable resin 1-1 that was modeled earlier. In this case, the distance by which the irradiation area of ​​the second photocurable resin 1-2 overlaps the irradiation area of ​​the first photocurable resin 1-1 (overlap amount) can be adjusted as needed. However, for example, it is preferable to set the overlap amount to at least 1 mm from the edge of the cured layer of the first photocurable resin 1-1 and less than half the length of the cured layer of the first photocurable resin 1-1. This configuration ensures an irradiation area where light can be reliably irradiated on the second photocurable resin 1-2 and prevents excessive irradiation of the second photocurable resin 1-2, thereby improving the modeling speed.

[0027] The corrected image data storage unit 35 stores the corrected design image data. Specifically, it stores design image data in which the irradiation area of ​​the second light-curable resin 1-2 to be modeled later in a predetermined layer has been corrected. With this configuration, for example, when multiple identical objects 2 are modeled, the second and subsequent objects can be modeled using the corrected design image data, thereby improving the modeling speed and modeling efficiency.

[0028] Next, the operation procedure of the image generation control device 30 according to this embodiment will be described. FIG. 2 is a flowchart showing the operation procedure of the image generation control device. FIG. 3 is a plan view showing an example of a shaped object showing a boundary portion. FIG. 4 is a diagram showing the procedure for shaping a shaped object. In this embodiment, as shown in FIG. 3, the shaped object 2 comprises a cured product 41 formed by curing the first photocurable resin 1-1 and a cured product 42 formed by curing the second photocurable resin 1-2, and these cured products 41 and 42 are in close contact with each other at a boundary portion 43 and are integrally shaped.

[0029] First, the image generation control device 30 determines the first layer (e.g., layer 1) (step S11), and reads out design image data for the target layer from the design image data storage unit 31 (step S12). Specifically, the image generation control device 30 reads out design image data from the design image data storage unit 31, which defines the irradiation areas of light (image light) corresponding to the first photocurable resin 1-1 and the second photocurable resin 1-2 of the first layer (layer 1) to be irradiated. This design image data defines the irradiation areas of light to be irradiated onto each of the multiple photocurable resins 1 that form a predetermined layer, and roughly corresponds to the cross-sectional shape of each layer when each photocurable resin 1 is cured.

[0030] Next, the image generation control device 30 detects, using the boundary portion detection unit 33, a boundary portion where the first photocurable resin 1-1, which is modeled first, and the second photocurable resin 1-2, which is modeled later, come into contact within the same layer (step S13). Specifically, the image generation control device 30 detects a portion where the light-irradiated regions corresponding to the first photocurable resin 1-1 and the second photocurable resin 1-2 come into contact within the first layer (the same layer) to be irradiated. This boundary portion corresponds to the boundary portion 43 shown in FIG. 3 where the cured product 41 and the cured product 42 come into contact within the same layer. The image generation control device 30 then determines whether a boundary portion has been detected within the same layer (step S14). If no boundary portion has been detected (step S14; No), the image generation control device 30 proceeds to step S16. Examples of cases in which the boundary portion is not detected include when the target layer is formed using a single photocurable resin 1, or when multiple photocurable resins 1 are formed at a distance from each other in the target layer.

[0031] On the other hand, if a boundary portion is detected in this determination (Step S14; Yes), the image generation control device 30 causes the image data correction unit 34 to correct the design image data for the detected boundary portion so that the irradiation area of ​​the second light-curable resin 1-2 to be modeled later overlaps the irradiation area of ​​the first light-curable resin 1-1 modeled earlier by a predetermined distance d (Step S15). In this configuration, the irradiation area of ​​the second light-curable resin 1-2 to be modeled later is corrected by expanding it in a direction that overlaps the irradiation area of ​​the first light-curable resin 1-1. This corrected design image data is stored in the corrected image data storage unit 35.

[0032] Next, based on the irradiation range of the design image data, the first photocurable resin 1-1 and the second photocurable resin 1-2 are sequentially irradiated with light (step S16).

[0033] Specifically, as shown in Fig. 4, (A) a photocurable resin layer of a predetermined thickness t made of a first photocurable resin 1-1 is formed between the platform 12 and the upper surface 14A of the light-transmitting plate 14, and image light L1 modulated by the image forming element 22 (Fig. 1) is irradiated onto a predetermined irradiation area 51 of this photocurable resin layer. Then, (B) the first photocurable resin 1-1 corresponding to the irradiation area 51 is cured, and a cured layer 41a of a predetermined thickness t that is part of the cured product 41 in Fig. 3 is formed.

[0034] Next, for example, after temporarily lifting the platform 12 upward, the modeling tank 11 storing the first photocurable resin 1-1 is replaced with the modeling tank 11 storing the second photocurable resin 1-2. (C) The platform 12 is then lowered to form a photocurable resin layer of the second photocurable resin 1-2 with a predetermined thickness t between the platform 12 and the upper surface 14A of the light-transmitting plate 14. In this case, since the second photocurable resin 1-2 is fluid, it is in contact with the edge of the cured layer 41a formed by the hardened first photocurable resin 1-1. In this state, the image light L2 modulated by the image forming element 22 (FIG. 1) is irradiated onto the corrected irradiation area 52A obtained by correcting the predetermined irradiation area 52 of the second photocurable resin 1-2. This corrected irradiation area 52A is corrected at the boundary with the irradiation area 51 of the cured layer 41a of the first photocurable resin 1-1 that was previously formed so that this irradiation area 51 and the irradiation area 52 of the second photocurable resin 1-2 overlap by a predetermined distance d.

[0035] This configuration ensures that a corrective irradiation area 52A, where light can be reliably irradiated, is secured at the boundary between the second photocurable resin 1-2 and the irradiation area 51 of the cured layer 41a of the first photocurable resin 1-1. Therefore, the second photocurable resin 1-2 corresponding to the irradiation area 52 (D) is cured to form a cured layer 42a of a predetermined thickness t, which is part of the cured product 42 shown in FIG. 3 . This cured layer 42a is tightly attached to the cured layer 41a of the first photocurable resin 1-1 without any gaps. This improves the adhesion between multiple photocurable resins 1 in the same layer, enabling the object 2 to be precisely molded.

[0036] Returning to the processing in FIG. 2, the description will be made again. Subsequently, the image generation control device 30 determines whether all layers have been formed (Step S17). The image generation control device 30 determines whether all layers of the target object 2 have been formed, for example, based on the schedule data stored in the formation schedule data storage unit 32. If it is determined that all layers have not been formed (Step S17; No), the image generation control device 30 sets the next layer (for example, layer 2) (Step S18) and executes the processing of Steps S12 to S18 for this next layer. On the other hand, if it is determined that all layers have been formed (Step S17; Yes), the image generation control device 30 concludes that the target object 2 has been formed and ends the processing.

[0037] The image generation control device 30 and the optical molding apparatus 10 according to this embodiment include: a design image data storage unit 31 that stores design image data in which light irradiation areas 51, 52 corresponding to the first photocurable resin 1-1 and the second photocurable resin 1-2 are defined for each layer of the object 2; a boundary portion detection unit 33 that detects, based on the design image data, a boundary portion 43 where the first photocurable resin 1-1 to be molded first and the second photocurable resin 1-2 to be molded later come into contact with each other within the same layer; and an image data correction unit 34 that corrects the design image data for the boundary portion 43 so that the irradiation area 52 of the second photocurable resin 1-2 overlaps the irradiation area 51 of the first photocurable resin 1-1. This configuration suppresses the effects of, for example, the mechanical precision of the platform 12 and the precision of the light irradiated to the irradiation areas 51, 52, and ensures appropriate adhesion between the first photocurable resin 1-1 and the second photocurable resin 1-2 at the boundary portion 43 within the same layer. Therefore, the object 2 can be formed with high precision.

[0038] The image generation control device 30 and the optical molding device 10 according to this embodiment are provided with a modified image data storage unit 35 that stores modified design image data. Therefore, for example, when creating multiple identical objects 2, the second and subsequent objects can be created using the modified design image data, thereby improving the creation speed and efficiency.

[0039] Furthermore, in the image generation control device 30 and the optical modeling device 10 according to this embodiment, the first photocurable resin 1-1 has the property of being cured by light with a shorter wavelength than the second photocurable resin 1-2, and therefore the light exposure accuracy of the first photocurable resin 1-1, which is modeled first, can be improved, and the modeled object 2 can be modeled with high precision.

[0040] [Second embodiment] Next, a photo-fabrication apparatus according to a second embodiment will be described. FIG. 5 is a schematic diagram showing the basic configuration of the photo-fabrication apparatus according to the second embodiment. FIG. 6 is a flowchart showing the procedure of the operation of the image generation control device. FIG. 7 is a perspective view showing an example of a molded object formed by molding one photo-curable resin within an area surrounded by a cured layer of the other photo-curable resin, from the bottom side. FIG. 8 is a diagram showing the procedure for molding a molded object. The same components as those in the above-mentioned embodiments are given the same reference numerals and their description will be omitted. Furthermore, in the second embodiment, unlike the first embodiment, the second photo-curable resin 1-2 has the property of being cured at a shorter wavelength than the first photo-curable resin 1-1.

[0041] In the optical shaping apparatus of the first embodiment described above, when multiple photocurable resins 1 are adjacent to each other in the same layer of the object 2, the adhesion between these photocurable resins 1 can be improved, thereby accurately shaping the object 2. In this configuration in which multiple photocurable resins 1 are adjacent to each other in the same layer of the object 2, it is assumed that, for example, one photocurable resin is completely surrounded by the other photocurable resin in the same layer of the object. In this case, when one photocurable resin is shaped in a recess (also called a depression; region) surrounded by the cured layer of the other photocurable resin, air trapped in the recess may prevent one photocurable resin from entering the recess, resulting in poor shaping of the object.

[0042] Therefore, in this second embodiment, the optical molding apparatus 110 accurately molds a molded object in which a first photocurable resin 1-1 (one of the photocurable resins) is placed within an area surrounded by a second photocurable resin 1-2 (the other of the photocurable resins), and as shown in Fig. 4, includes a plurality of (two in Fig. 1) molding tanks 11, 11, a platform 12, a light irradiation unit 20, and an image generation control device 130. The image generation control device 130 includes a design image data storage unit 131, a molding schedule data storage unit 132, an area detection unit 133, a schedule correction unit 134, and a corrected schedule data storage unit 135. Furthermore, the object 102 formed by the photopolymerization device 110 comprises, for example, a hardened product 61 formed by hardening a first photocurable resin 1-1 (one of the photocurable resins) and a hardened product 62 formed by hardening a second photocurable resin 1-2 (the other of the photocurable resins), as shown in FIG. 7, and the hardened product 61 is integrally formed within a recess 63 (area) surrounded on all sides by the hardened product 62.

[0043] Like the design image data storage unit 31 described above, the design image data storage unit 131 stores design image data that defines irradiation areas of light (image light) corresponding to the types of photocurable resin 1 (first photocurable resin 1-1 and second photocurable resin 1-2) in each layer (each cured layer) when forming the target object 2. In this embodiment, the design image data is assumed to be in a region in a predetermined layer where the irradiation area of ​​the first photocurable resin 1-1 is surrounded on all sides by the irradiation area of ​​the second photocurable resin 1-2. If the target object 102 is formed of k layers (k is a natural number), the design image data storage unit 131 stores design image data that defines irradiation areas of light (image light) corresponding to each photocurable resin 1 in all layers from the first layer to the kth layer.

[0044] The modeling schedule data storage unit 132 stores schedule data indicating the modeling order of the photocurable resin 1 in a predetermined layer of the modeled object 102. That is, the modeling schedule data storage unit 132 stores schedule data that specifies, for each layer, whether the first photocurable resin 1-1 or the second photocurable resin 1-2 should be modeled first. Even in this embodiment, unless there is a special reason, the modeling schedule data storage unit 132 stores schedule data that specifies that the photocurable resin 1 (second photocurable resin 1-2) that is cured with light having a shorter wavelength should be modeled first in each layer. With this configuration, light with a shorter wavelength has higher exposure accuracy, and therefore the modeled object 102 can be modeled with high accuracy.

[0045] Based on the design image data, the region detection unit 133 detects a recess (region) within the same layer to be modeled, where one photocurable resin is completely surrounded by the other photocurable resin. Specifically, it detects a recess formed when one of the first photocurable resin 1-1 and the second photocurable resin 1-2 is completely surrounded by the other of the first photocurable resin 1-1 and the second photocurable resin 1-2. In this case, the surrounding photocurable resin and the surrounding photocurable resin are different types, but this does not apply if they are the same type of photocurable resin. Furthermore, in the example of FIG. 7, the recess 63 completely surrounded by the cured product 62 has the cured product 61 disposed therein with a gap therebetween. However, in the recess 63 completely surrounded by the cured product 62, the edge of the cured product 62 and the edge of the cured product 61 may be in close contact with each other.

[0046] If the schedule indicates that the other photocurable resin is to be modeled before the one photocurable resin for the detected recess, the schedule correction unit 134 corrects the schedule data so that the one photocurable resin is modeled before the other photocurable resin. In this embodiment, the schedule data indicates that the second photocurable resin 1-2 (the other photocurable resin), which is cured with light having a shorter wavelength, is modeled before the first photocurable resin 1-1 (the one photocurable resin). Therefore, in the example of FIG. 7 , the modeled object 102 is first modeled as a cured product 62 obtained by curing the second photocurable resin 1-2, and then a cured product 61 obtained by curing the first photocurable resin 1-1 is modeled in the recess 63 completely surrounded by the cured product 62. Therefore, the schedule correction unit 134 corrects the schedule data so that the first photocurable resin 1-1 is modeled before the second photocurable resin 1-2 for the recess 63.

[0047] The modified schedule data storage unit 135 stores the modified schedule data. Specifically, it stores schedule data in which the modeling order of the recessed portions 63 that are completely surrounded in a predetermined layer is modified. With this configuration, for example, when multiple identical objects 2 are to be modeled, the second and subsequent objects can be modeled using the modified schedule data, thereby improving the modeling speed and modeling efficiency.

[0048] Next, the procedure of the operation of the image generation control device 130 according to this embodiment will be described. First, as shown in FIG. 6, the image generation control device 130 determines the first layer (e.g., layer 1) (step S21) and reads out design image data for the target layer from the design image data storage unit 131 (step S22). In detail, the image generation control device 130 reads out design image data from the design image data storage unit 131, which defines the irradiation areas of light (image light) corresponding to the first photocurable resin 1-1 and the second photocurable resin 1-2 of the first layer (layer 1) to be irradiated. This design image data defines the irradiation areas of light to be irradiated on each of the multiple photocurable resins 1 that form a predetermined layer, and roughly corresponds to the cross-sectional shape of each layer when each photocurable resin 1 is cured.

[0049] Next, the image generation control device 130 reads out schedule data that specifies the modeling order of target layers from the modeling schedule data storage unit 132 (Step S23). Specifically, the image generation control device 130 reads out schedule data that specifies that the second photocurable resin 1-2 is modeled before the first photocurable resin 1-1 in the first layer (same layer) to be irradiated. Next, the image generation control device 130 searches, using the region detection unit 133, for a recess in the same layer where the first photocurable resin 1-1 is present and is completely surrounded by the second photocurable resin 1-2 (Step S24). This recess corresponds to the recess 63 in FIG. 7 where the cured product 61 is present and is completely surrounded by the cured product 62. Then, the image generation control device 130 determines whether or not there is a recess in the same layer where the first photocurable resin 1-1 is present (Step S25). In this determination, if a recess where the first photocurable resin 1-1 is present is not detected (step S25; No), the image generation control device 130 proceeds to step S27. Examples of cases where a recess where the first photocurable resin 1-1 is present may include when the target layer is formed with a single photocurable resin 1, or when a recess surrounded on all sides by the second photocurable resin 1-2 exists but the first photocurable resin is not present in this recess.

[0050] On the other hand, if a recess in which the first light curable resin 1-1 is present is detected in this determination (step S25; Yes), the image generation control device 130 causes the schedule correction unit 134 to correct the schedule data for the detected recess so that the first light curable resin 1-1 in the recess is molded before the second light curable resin 1-2 (step S26). In this configuration, the schedule data for the recess is corrected so that the first light curable resin 1-1 is molded before the second light curable resin 1-2. This corrected schedule data is stored in the corrected schedule data storage unit 135.

[0051] Next, the first light curable resin 1-1 and the second light curable resin 1-2 are sequentially irradiated with light in accordance with the modeling order of the schedule data (step S27).

[0052] 8, (A) a photocurable resin layer of a predetermined thickness t made of a first photocurable resin 1-1 is formed between the platform 12 and the upper surface 14A of the light-transmitting plate 14, and a predetermined irradiation area 53 of this photocurable resin layer is irradiated with image light L1 modulated by the image forming element 22 (FIG. 1). Then, (B) the first photocurable resin 1-1 corresponding to the irradiation area 53 is cured, and a cured layer 61a of a predetermined thickness t is formed.

[0053] Next, for example, after temporarily raising the platform 12, the modeling tank 11 storing the first photocurable resin 1-1 is replaced with the modeling tank 11 storing the second photocurable resin 1-2. (C) The platform 12 is then lowered to form a photocurable resin layer of a predetermined thickness t made of the second photocurable resin 1-2 between the platform 12 and the upper surface 14A of the light-transmitting plate 14. In this case, since the second photocurable resin 1-2 has fluidity, it is in contact with the edge of the cured layer 61a formed by the hardening of the first photocurable resin 1-1. In this state, image light L2 modulated by the image forming element 22 (FIG. 1) is irradiated onto a predetermined irradiation area 54 of the second photocurable resin 1-2 surrounding the cured layer 61a.

[0054] According to this configuration, the cured layer 62a formed by curing the second photocurable resin 1-2 corresponding to the (D) irradiation region 54 is formed so as to surround the cured layer 61a of the first photocurable resin 1-1, and this cured layer 61a is disposed in the recess 63 surrounded on all sides by the cured layer 62a. Therefore, it is possible to precisely form the object 102 in which one photocurable resin is disposed within the region surrounded by the other photocurable resin.

[0055] Returning to the processing in Fig. 6, the description will be made again. Subsequently, the image generation control device 130 determines whether or not all layers have been formed (Step S28). The image generation control device 130 determines whether or not all layers of the target object 102 have been formed, for example, based on the schedule data stored in the formation schedule data storage unit 132. If it is determined that all layers have not been formed (Step S28; No), the image generation control device 130 sets the next layer (for example, layer 2) (Step S29) and executes the processing of Steps S22 to S29 for this next layer. On the other hand, if it is determined that all layers have been formed (Step S28; Yes), the image generation control device 130 concludes that the target object 102 has been formed and ends the processing.

[0056] The image generation control device 130 and the optical molding device 110 according to this embodiment include a design image data storage unit 131 that stores design image data in which light irradiation areas 53, 54 corresponding to the first photocurable resin 1-1 and the second photocurable resin 1-2 are respectively defined for each layer of the molded object 102; a molding schedule data storage unit 132 that stores schedule data indicating the molding order of the first photocurable resin 1-1 and the second photocurable resin 1-2 in each layer of the molded object 102; a region detection unit 133 that detects, based on the design image data, a recess 63 in the same layer in which the first photocurable resin 1-1 is surrounded on all sides by the second photocurable resin 1-2; and a schedule correction unit 134 that corrects the schedule data for the detected recess 63 so that the first photocurable resin 1-1 is molded before the second photocurable resin 1-2 if the schedule indicates that the second photocurable resin 1-2 is to be molded before the first photocurable resin 1-1. This configuration makes it possible to appropriately prevent air trapped in the recess 63 surrounded by the cured product 62 of the second photocurable resin 1-2 from obstructing the entry of the first photocurable resin 1-1 into the recess 63. This makes it possible to accurately mold the object 102 in which the first photocurable resin 1-1 (one of the photocurable resins) is placed in a region surrounded by the second photocurable resin 1-2 (the other photocurable resin).

[0057] The image generation control device 130 and the optical fabrication device 110 according to this embodiment are provided with a modified schedule data storage unit 135 that stores modified schedule data. Therefore, for example, when forming multiple identical objects 102, the second and subsequent objects can be formed using the modified schedule data, thereby improving the fabrication speed and fabrication efficiency.

[0058] The image generation control device 30, 130 according to the present invention and the optical shaping apparatus 10, 110 equipped with the same have been described above, but the present invention may be embodied in various different forms other than the above-described embodiments. Furthermore, the components of the illustrated optical shaping apparatus are functionally conceptual and do not necessarily have to be physically configured as shown. In other words, the specific form of each device is not limited to that shown in the drawings, and all or part of the devices may be functionally or physically distributed or integrated in any unit depending on the processing load and usage status of each device.

[0059] The configuration of the image generation control devices 30 and 130 is realized, for example, as software, by a program loaded into memory. In the above embodiment, these functional blocks are described as being realized by the cooperation of these hardware and software. In other words, these functional blocks can be realized in various forms, using only hardware, only software, or a combination of both. [Explanation of symbols]

[0060] 1 Photocurable resin 1-1 First photocurable resin (one of the photocurable resins) 1-2 Second photocurable resin (the other photocurable resin) 2, 102 Modeled objects 10, 110 Stereolithography equipment 11 Modeling tank 12 Platform 14 Light-transmitting plate 14A Top 21 Light source 22 Image forming element 30, 130 Image generation control device 31, 131 Design image data storage unit 32, 132 Modeling schedule data storage unit 33 Boundary detection unit 34 Image data correction section 35 Corrected image data storage unit 41, 42, 61, 62 cured product 41a, 42a, 61a, 62a hardened layer 43 Boundary part 51, 52, 53, 54 Irradiation area 52A Modified irradiation area 63 Recess (area) 133 Area detection unit 134 Schedule Correction Department 135 Correction schedule data storage unit d predetermined distance L1 Image light (light) L2 Image light (light)

Claims

1. An image generation control device that controls light that is irradiated onto a photocurable resin adjusted to a predetermined thickness and that hardens the photocurable resin to form a model layer by layer, a design image data storage unit that stores design image data in which the light irradiation regions corresponding to one or more types of the photocurable resin are defined for each layer of the object; a boundary portion detection unit that detects a boundary portion where one photocurable resin to be modeled first and another photocurable resin to be modeled later come into contact with each other within the same layer, based on the design image data; an image data correcting unit that corrects the design image data so that the irradiation area of ​​the other photocurable resin overlaps with the irradiation area of ​​the one photocurable resin with respect to the boundary portion; An image generation control device including:

2. 2. The image generation control device according to claim 1, further comprising a corrected image data storage unit for storing the corrected design image data.

3. 3. The image generation control device according to claim 1, wherein the one photocurable resin has a property of being cured by the light having a shorter wavelength than the other photocurable resin.

4. a modeling tank that stores a photocurable resin and has a light-transmitting portion on its bottom surface; a light irradiation unit that irradiates light that cures the photocurable resin through the light transmission unit; a platform facing the light transmitting unit and capable of moving up and down relative to the modeling tank; an image generation control device that controls light that is irradiated from the light irradiation unit onto the photocurable resin adjusted to a predetermined thickness, to cure the photocurable resin and form a model layer by layer, The image generation control device includes: a design image data storage unit that stores design image data in which the light irradiation regions corresponding to one or more types of the photocurable resin are defined for each layer of the object; a boundary portion detection unit that detects a boundary portion where one photocurable resin to be modeled first and another photocurable resin to be modeled later come into contact with each other within the same layer, based on the design image data; an image data correcting unit that corrects the design image data so that the irradiation area of ​​the other photocurable resin overlaps with the irradiation area of ​​the one photocurable resin with respect to the boundary portion; A stereolithography device comprising:

Images