Method for repairing a molded object, molding system, and method for manufacturing an attachment member

Abstract

To make easy and appropriate repairs to damaged molding objects.SOLUTION: A method of repairing a molding object comprises: a preparation stage for preparing a part for a defective part to be attached to a defective portion in a molding object to be repaired; an affixed member creation stage for creating a repair patch 300, which is an affixed member to be affixed to at least part of the surface of the molding object to be repaired; and an attachment stage for attaching the repair patch 300 so as to cover at least part of the border area between the molding object to be repaired and the part for the defective part. At least part of the surface of the molding object to be repaired is colored, and in the affixed member creation stage, the repair patch 300 with a coloring layer 302 and an adhesive layer 304 is created using a molding device capable of molding the colored molding object by the laminated molding method, and the coloring layer 302 is formed by coloring it to match the color of the part to be covered by the repair patch 300 in a molding object 50.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to a method for repairing a shaped object, a shaping system, and a method for manufacturing an attachment member. [Background technology]

[0002] Conventionally, there has been known a modeling apparatus (3D printer) that uses an inkjet head to form a model (see, for example, Patent Document 1). In such a modeling apparatus, for example, an object is formed by layering ink layers formed by the inkjet head, using a layered modeling method. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2015-071282 Summary of the Invention [Problem to be solved by the invention]

[0004] In the case of a modeling apparatus, even if the model is damaged, it is usually possible to remodel the same model. However, depending on the purpose of the model and the type of damage, it may be more desirable to repair the damaged model rather than remodel the same model. In such cases, repairing the model by gluing the damaged area may be considered. However, repairing the model in this manner may result in a decrease in the strength of the repaired area, making the same area more susceptible to further damage. Therefore, a more appropriate method for repairing a model is desired. Therefore, an object of the present invention is to provide a method for repairing a model, a modeling system, and a method for manufacturing an attachment member that can solve the above-mentioned problems. [Means for solving the problem]

[0005] The inventors of the present application conducted extensive research into methods for repairing objects modeled using a modeling apparatus. They came up with the idea of ​​reinforcing a damaged area by attaching a patch-shaped member (hereinafter referred to as a repair patch) to at least a portion of the periphery of the damaged area, rather than simply gluing the damaged area. However, in this case, the repair patch remaining on the surface of the repaired object may detract from the appearance of the repaired object. In particular, repairing an object with a colored surface using this method may significantly detract from its appearance. In response to this, the inventors of the present application conducted further research and came up with the idea of ​​creating a repair patch that matches the repair position on the object to be repaired. Furthermore, in this case, they came up with the idea of ​​creating a repair patch that is colored to match the repair position on the object to be repaired using a modeling apparatus capable of forming an object identical or similar to the object to be repaired. With this configuration, for example, the use of the repair patch can appropriately increase the strength of the repaired object. Furthermore, by using a repair patch that is colored to match the repair position, it is possible to appropriately prevent the repair patch from being excessively conspicuous when attached to a modeled object.Furthermore, by creating the repair patch using a modeling device, it is possible to easily and appropriately create a repair patch that is colored to match the repair position.

[0006] Furthermore, the inventors of the present application have further intensively researched and found the features necessary to achieve such effects, and have arrived at the present invention. In order to solve the above-mentioned problems, the present invention provides a method for repairing a modeled object modeled by a modeling apparatus, the method comprising: a preparation step of preparing a part for missing portion, which is a member to be attached to a missing portion of a modeled object to be repaired, the modeled object being damaged and resulting in a partial loss; an attachment member creation step of creating an attachment member to be attached to at least a portion of the surface of the modeled object to be repaired and the part for missing portion; and a step of attaching the part for missing portion to a portion of the boundary between the modeled object to be repaired and the part for missing portion while the modeled object to be repaired and the part for missing portion are brought into contact with each other. and an attaching step of attaching the attaching member so as to cover at least a portion of the surface of the object to be repaired, wherein at least a portion of the surface of the object to be repaired is colored. In the attaching member creating step, a modeling device capable of creating the colored object by additive manufacturing is used to create the attaching member, which includes an adhesive layer that is a layer for adhering the attaching member to the object to be repaired and the part for the missing portion, and a colored layer that is a colored layer, and the colored layer is formed by coloring the colored layer to match the color of the portion of the object to be repaired that will be covered by the attaching member.

[0007] With this configuration, by attaching an attachment member to at least a portion of the repair position on the object to be repaired, it is possible to appropriately increase the strength of the object to be repaired, for example. Furthermore, by using an attachment member that includes a colored layer and an adhesive layer, it is possible to easily and appropriately create an attachment member that is appropriately colored and adhered to the object to be repaired, for example, using a modeling device. Furthermore, by coloring the colored layer of the attachment member to match the color of the portion of the object to be repaired that will be covered by the attachment member, it is possible to appropriately prevent the attachment member from being excessively noticeable on the object to be repaired, for example. Therefore, with this configuration, it is possible to easily and appropriately repair the object to be repaired, for example.

[0008] In this configuration, a patch-shaped member (repair patch) may be used as the affixing member. This configuration makes it possible to easily and appropriately affix the affixing member to the correction-target object. For example, a portion that has been removed from the correction-target object due to damage may be used as the part for the missing portion. This configuration makes it possible to easily and appropriately prepare the part for the missing portion. In this case, for example, the portion of the object before the damage, excluding the part for the missing portion, may be considered to be the object to be repaired. Furthermore, the object to be repaired may also be considered to have a configuration corresponding to at least a portion of the object before the damage occurred. Depending on the state of the damage and the required quality of the repair, it may be possible to use a part newly created for the repair as the part for the missing portion, rather than a portion of the object before the damage. In this case, for example, it may be possible to further create (model) the part for the missing portion using the modeling device used to create the affixing member. Furthermore, it is preferable that the method for repairing an object further includes, for example, an adhering step of adhering the part for the missing portion to the object to be repaired. In this case, it is conceivable to perform the operation of the adhering step after the operation of the bonding step, which makes it possible to more appropriately fix the part for the missing portion to the object to be repaired, for example.

[0009] Preferably, the method for repairing a structure further includes a repair position designation step of receiving, from a user, a designation of a repair position, which is a position on the structure to be repaired, on the repair-target object. In this case, in the repair position designation step, for example, an image showing at least a portion of the structure to be repaired is displayed on an image display device, and the designation of the repair position is received from the user. Then, in the attachment member creation step, for example, the shape of the attachment member and the color of each position in the colored layer are determined in accordance with the repair position designated in the repair position designation step. The attachment member is created based on the determined shape and color. With this configuration, for example, attachment members tailored to the repair positions can be more appropriately created based on the user's designation.

[0010] Furthermore, in the attachment member creation stage, the attachment member may be created based on, for example, data used when the object to be repaired was modeled. In this case, the modeling of the object to be repaired can be considered to be, for example, the modeling of the object before it was damaged, using a modeling device. Furthermore, as such data, for example, object data indicating the shape and color of the object may be used. More specifically, in this case, in the attachment member creation stage, the color of each position in the colored layer of the attachment member is determined based on, for example, the object data indicating the shape and color of the object to be repaired, which was used when the object to be repaired was modeled. Then, the attachment member is created based on the determined color. With this configuration, for example, the color of the portion of the object to be repaired that will be covered by the attachment member can be appropriately obtained based on the object data. Furthermore, this allows, for example, the color of the colored layer of the attachment member to be appropriately colored to match the color of the portion of the object to be repaired that will be covered by the attachment member.

[0011] The color of the portion of the object to be repaired that is covered by the affixing member may be obtained directly from the object to be repaired, without using the object data. In this case, the method for repairing an object further includes, for example, a data generation step of generating scan data obtained by 3D scanning the object to be repaired. In this case, the affixing member creation step determines the color of each position in the colored layer of the affixing member based on the scan data generated in the data generation step. The affixing member is then created based on the determined color. This configuration also makes it possible to appropriately obtain the color of the portion of the object to be repaired that is covered by the affixing member. This also makes it possible to appropriately color the colored layer of the affixing member to match the color of the portion of the object to be repaired that is covered by the affixing member. In addition, in the data generation step, for example, a part for the missing portion may also be scanned. More specifically, in this case, for example, 3D scanning may be performed with the part for the missing portion attached to the object to be repaired. With this configuration, for example, it is possible to properly obtain the colors of the portions of the object to be repaired and the part for missing portion that are covered by the adhesive member, and it is also possible to more properly determine the colors of each position of the colored layer of the adhesive member.

[0012] In this configuration, the object to be repaired includes, for example, a colored region that is colored on the surface of the object to be repaired and a light-reflecting region formed inside the colored region with light reflectivity. The modeling device used in the attachment member creation stage may be a device capable of modeling such an object. More specifically, the modeling device used in the attachment member creation stage may be a device that dispenses an ultraviolet-curable material as the modeling material. In this case, the modeling device may include, for example, multiple ejection heads that each eject a modeling material and an ultraviolet light source that irradiates the ejected modeling material with ultraviolet light. The multiple ejection heads may include at least a coloring material head that dispenses a colored material, which is a colored modeling material for coloring, and a light-reflective material head that dispenses a light-reflective modeling material, which is a light-reflective modeling material. This configuration makes it possible to appropriately create an attachment member with a configuration tailored to the object to be repaired, for example.

[0013] In this case, the UV-curable material used as the modeling material can be made tacky by, for example, irradiating it with UV light at a level less than the level required for complete curing. The adhesive layer of the attachment member can be formed by making the modeling material tacky. More specifically, in this case, in the attachment member creation stage, the colored layer is formed using at least a colored material ejected from a coloring material head. The colored layer can be formed by, for example, irradiating the modeling material with a sufficient amount of UV light to harden it to a non-tacky state. The adhesive layer can also be formed using a modeling material ejected from one of multiple ejection heads. Furthermore, during the formation of the adhesive layer, the viscosity of the modeling material can be increased to a tacky state by irradiating the modeling material with UV light from an UV light source. In this case, in the attachment stage, for example, after attaching the attachment member to the object to be repaired, the modeling material in the adhesive layer can be hardened by further irradiating the attachment member with UV light. With this configuration, for example, the adhesive layer of the attachment member can be properly formed using an ultraviolet-curable modeling material. Furthermore, after attaching the attachment member to the object to be repaired, further irradiation with ultraviolet light is performed to complete the curing of the adhesive layer, thereby properly fixing the attachment member to the object to be repaired.

[0014] In addition, as a modified example of the method for forming the adhesive layer of the attachment member, it is possible to form the adhesive layer using an adhesive material that is not used as a modeling material when forming a normal object. In this case, the material that is not used as a modeling material when forming a normal object can be considered, for example, as a material that is not used when forming an object identical to the object to be repaired. The adhesive material can also be considered, for example, as a material for the adhesive layer of the attachment member that is not used when forming the same areas as the colored areas and light-reflecting areas of the object to be repaired. In this case, the modeling device used to create the attachment member further includes, for example, an adhesive material head that dispenses the adhesive material. In addition, in the attachment member creation stage, for example, the colored layer is formed using at least a colored material dispensed from the coloring material head. Then, the adhesive layer is formed using the adhesive material dispensed from the adhesive material head. Even with this configuration, an attachment member including a colored layer and an adhesive layer can be appropriately created. Furthermore, as such an adhesive material, for example, an ultraviolet-curable material that maintains its adhesiveness even after sufficient ultraviolet irradiation and curing are completed may be used. More specifically, as such an adhesive material, for example, a liquid that is the same as or similar to a known ultraviolet-curable ink (primer ink) used for forming a base may be used. Furthermore, as an adhesive material that is not used as a modeling material during the modeling of a normal object, for example, a non-UV-curable adhesive material may be used. When such an adhesive material is used, it is possible to complete the attachment of the attachment member to the object to be repaired in the attachment stage, for example, without further irradiation of ultraviolet light. Even with this configuration, for example, the attachment member can be appropriately attached to the object to be repaired.

[0015] Furthermore, as a configuration of the present invention, it is also conceivable to use a modeling system or a manufacturing method for an attachment member having the same characteristics as those described above. In these cases, for example, the same effects as those described above can be obtained. [Effects of the Invention]

[0016] According to the present invention, for example, a damaged shaped object can be easily and appropriately repaired. [Brief explanation of the drawings]

[0017] [Figure 1] 1A and 1B are diagrams illustrating a modeling system 10 used in a method for repairing a modeled object according to an embodiment of the present invention. FIG. 1A shows an example of the configuration of the modeling system 10. FIG. 1B shows an example of the configuration of a main part of a modeling device 12 in the modeling system 10. FIG. 1C shows an example of the configuration of a head unit 102. [Figure 2] 2A and 2B are diagrams illustrating a model 50 formed by the modeling device 12 of this example and an operation for repairing the model 50. FIG. 2A shows an example of the configuration of the model 50. FIG. 2B shows an example of how damage occurs in the model 50. FIG. 2C shows an example of the configuration of a repair patch 300. [Figure 3] 3A and 3B are diagrams illustrating in more detail the operation of repairing the object 50 using the repair patch 300. FIGS. 3A and 3B show an example of the configuration of the repair patch 300. FIG. 3C shows an example of how to apply the repair patch 300 to the object 50 to be repaired. FIG. 3D is a cross-sectional view showing an example of the cross-sectional configuration of the object 50 and the repair patch 300 at the position where the repair patch 300 is applied. [Figure 4] 10 is a flowchart showing an example of an operation for repairing a shaped object 50. [Figure 5] 10 is a flowchart illustrating an example of an operation for generating patch data. [Figure 6] 6A and 6B are diagrams illustrating modified examples of the configuration of the repair patch 300. Figures 6A and 6B show modified examples of the configuration of the repair patch 300. Figure 6C shows a modified example of the configuration of the head portion 102. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a diagram illustrating a modeling system 10 used in a method for repairing a modeled object according to an embodiment of the present invention. FIG. 1(a) shows an example of the configuration of the modeling system 10. FIG. 1(b) shows an example of the configuration of a main part of a modeling device 12 in the modeling system 10. In this example, the modeling system 10 is a modeling system that models a three-dimensional modeled object and includes a modeling device 12 and a control PC 14. The modeled object modeled by the modeling system 10 can be considered to be, for example, a three-dimensional structure. In this example, the modeling system 10 is configured by multiple devices, namely, the modeling device 12 and the control PC 14. In a modified example of the modeling system 10, the modeling system 10 may be configured by a single device. In this case, for example, the modeling system 10 may be configured by a single modeling device 12 that includes the functions of the control PC 14. The modeling system 10 may further include devices other than the modeling device 12 and the control PC 14.

[0019] In the modeling system 10, the modeling device 12 is a device that executes modeling of a modeled object and models the modeled object under the control of the control PC 14. In this example, the modeling device 12 is a full-color modeling device capable of modeling a full-color modeled object. The modeling device 12 receives model data representing the object to be modeled from the control PC 14 and models the object based on the model data. The modeling device 12 is a modeling device (3D printer) that models a three-dimensional modeled object 50 using an additive manufacturing method. As shown in FIG. 1( b), the modeling device 12 includes a head unit 102, a modeling table 104, a scan driver 106, and a controller 110. In this case, the additive manufacturing method can be considered to be, for example, a method of modeling the modeled object 50 by stacking layers formed of a modeling material. Except as described below, the modeling device 12 may have the same or similar configuration as a known modeling device. More specifically, except for the points described below, the modeling device 12 may have the same or similar features as a known modeling device that uses an inkjet head to eject droplets that will become the material for the modeled object 50. Furthermore, the modeling device 12 may further include, in addition to the components shown in the drawings, various components necessary for, for example, modeling the modeled object 50.

[0020] The head unit 102 is configured to eject the material of the object 50. In this example, ink is used as the material of the object 50. The ink can be considered, for example, as a functional liquid. The ink can also be considered, for example, as a liquid ejected from an inkjet head. In this example, the head unit 102 ejects ink that hardens under predetermined conditions from multiple inkjet heads as the material of the object 50. The ink is then cured after impact to form the layers that make up the object 50, thereby forming the object using an additive manufacturing method. In this example, ultraviolet-curable ink (UV ink) that hardens from a liquid state upon exposure to ultraviolet light is used as such ink. In this case, the ultraviolet-curable ink is an example of an ultraviolet-curable modeling material. In addition to the material of the object 50, the head unit 102 also ejects the material of the support layer 52. As a result, the head unit 102 forms the support layer 52 around the object 50 as needed. The support layer 52 can be considered, for example, as a laminated structure that supports at least a part of the object 50 during modeling. The support layer 52 is formed as needed during modeling of the object 50, and is removed after modeling is completed.

[0021] The modeling table 104 is a platform-like member that supports the object 50 being modeled. It is disposed in a position facing the inkjet head of the head unit 102, and the object 50 being modeled and the support layer 52 are placed on its upper surface. In this example, the modeling table 104 is configured to be movable in the stacking direction (Z direction in the figure), and is driven by the scan driver 106 to move in the stacking direction in accordance with the progress of modeling of the object 50. In this case, the stacking direction can be considered, for example, as the direction in which modeling materials are stacked in an additive manufacturing method. In this example, the stacking direction is a direction perpendicular to the main scanning direction (Y direction in the figure) and sub-scanning direction (X direction in the figure) that are preset in the modeling device 12.

[0022] The scan driver 106 is a driver that causes the head unit 102 to perform a scanning operation in which the head unit 102 moves relative to the object 50 being modeled. In this example, the movement relative to the object 50 being modeled can be considered, for example, to be movement relative to the modeling table 104. Also, causing the head unit 102 to perform a scanning operation can be considered, for example, to be causing an inkjet head included in the head unit 102 to perform a scanning operation. Also, in this example, the scan driver 106 causes the head unit 102 to perform a main scanning operation (Y scan), a sub-scanning operation (X scan), and a stacking direction scanning operation (Z scan) as scanning operations. In this case, the main scanning operation can be considered, for example, to be an operation of ejecting ink while moving in the main scanning direction relative to the object 50 being modeled. The sub-scanning operation can be considered, for example, to be an operation of moving relative to the object 50 being modeled in the sub-scanning direction perpendicular to the main scanning direction. The sub-scanning operation can also be considered to be, for example, an operation of moving the head unit 102 in the sub-scanning direction by a preset feed amount relative to the modeling table 104. In this example, the scan driver 106 causes the head unit 102 to perform the main scanning operation and the sub-scanning operation, thereby causing the head unit 102 to form an ink layer. The stacking direction scanning operation can also be considered to be, for example, an operation of moving in the stacking direction relative to the object 50 being modeled. The scan driver 106 adjusts the relative position of the inkjet head with respect to the object 50 being modeled in the stacking direction by causing the head unit 102 to perform the stacking direction scanning operation in accordance with the progress of the modeling operation.

[0023] The control unit 110 includes, for example, a CPU of the modeling apparatus 12, and controls each unit of the modeling apparatus 12 to control the modeling operation of the object 50. In this example, the control unit 110 generates slice data, which is data representing a cross section of the object 50 to be modeled, based on the object data received from the control PC 14. Then, in the operation of forming each ink layer that constitutes the object 50, the control unit 110 controls the operation of each inkjet head in the head unit 102 based on the slice data, thereby causing each inkjet head to eject the ink used to model the object. According to this example, for example, the modeling of the object 50 can be performed appropriately.

[0024] In this example, the modeling device 12 also creates repair patches, which are components used to repair objects, in addition to the normal object. In this case, the normal object can be considered to be, for example, an object modeled by the modeling device 12 through normal modeling operations. The repair patch can be considered to be, for example, a component used to repair an object previously modeled by the modeling device 12 that creates the repair patch, or by another modeling device. The operation of creating the repair patch in this example and how to use the repair patch will be described in more detail later.

[0025] In the modeling system 10, the control PC 14 is a computer (host PC) that controls the operation of the modeling apparatus 12 and controls the modeling operation of the modeling apparatus 12 by supplying modeling object data to the modeling apparatus 12. In this example, the control PC 14 has a display unit 22, an operation unit 24, and a main body unit 26, and supplies modeling object data representing a model having a colored surface whose color is visible from the outside to the modeling apparatus 12. The display unit 22 is an example of an image display device and displays various information to a user of the control PC 14. The display unit 22 can be considered to correspond to, for example, a computer monitor. The operation unit 24 is a component that receives user operations to input information from the user. The operation unit 24 can be considered to correspond to, for example, an input device such as a computer mouse or keyboard. The main body unit 26 is a component that executes various processes in the control PC 14. The main body unit 26 can be considered to correspond to, for example, a computer main body.

[0026] In this example, the control PC 14 is an example of a control device that controls the operation of the modeling apparatus 12, and supplies, for example, modeled object data received from outside the modeling system 10 to the modeling apparatus 12. With this configuration, for example, the modeled object data can be appropriately supplied to the modeling apparatus 12. This also enables the modeling system 10 to appropriately model an object. In this case, the control PC 14 may adjust the modeled object data received from outside to match the configuration, status, etc. of the modeling apparatus 12, and then supply the adjusted data to the modeling apparatus 12. In this example, when creating a repair patch in the modeling apparatus 12, the control PC 14 supplies modeled object data indicating the repair patch to the modeling apparatus 12. With this configuration, for example, it is possible to cause the modeling apparatus 12 to appropriately create the repair patch. In addition, the modeled object data may be generated by the control PC 14 in response to, for example, a user's instruction or operation, rather than being received from outside the modeling system 10. For example, when the modeling device 12 is made to create a repair patch, it is possible to generate the modeling object data indicating the repair patch in the control PC 14. Even in such a configuration, it is possible to appropriately supply the modeling object data to the modeling device 12, for example.

[0027] Next, the configuration of the head unit 102 in the modeling apparatus 12 will be described in more detail. FIG. 1( c) shows an example of the configuration of the head unit 102. In this example, the head unit 102 has multiple inkjet heads 202, multiple ultraviolet light sources 204, and a flattening roller 206. The multiple inkjet heads 202 are distinguished by the letters s to t in the figure, and include inkjet head 202s, inkjet head 202w, inkjet head 202y, inkjet head 202m, inkjet head 202c, inkjet head 202k, and inkjet head 202t. These multiple inkjet heads 202 are aligned in the main scanning direction with their positions aligned in the sub-scanning direction. Each inkjet head 202 has a nozzle row on the surface facing the modeling table 104, with multiple nozzles aligned in a predetermined nozzle row direction. In this example, the nozzle row direction is parallel to the sub-scanning direction.

[0028] Among these inkjet heads 202, inkjet head 202s is an inkjet head that ejects the material of support layer 52. For example, a known material for support layers can be suitably used as the material of support layer 52. The inkjet heads 202 other than inkjet head 202s are inkjet heads that eject the material of the model 50. In this example, the inkjet heads 202 other than inkjet head 202s can be considered, for example, as an example of an ejection head that ejects the modeling material that constitutes the model 50. Among the inkjet heads 202 other than inkjet head 202s, inkjet head 202w is an inkjet head that ejects white (W) ink. In this example, inkjet head 202w is an example of a light-reflective material head that ejects a light-reflective material, which is a light-reflective modeling material. White ink is an example of a light-reflective material, and is used, for example, to form a region (light-reflective region) that reflects light in the model 50. This light-reflecting region reflects light incident from outside the shaped object 50, for example, when coloring the surface of the shaped object 50 in full color. Full color expression can be considered, for example, as color expression achieved by a possible combination of process color inks using a subtractive color mixing method. Process colors can be considered, for example, as basic colors used in color expression.

[0029] Inkjet head 202y, inkjet head 202m, inkjet head 202c, and inkjet head 202k (hereinafter referred to as inkjet heads 202y-k) are inkjet heads for coloring used when forming a colored object 50. More specifically, inkjet head 202y ejects yellow (Y) ink. Inkjet head 202m ejects magenta (M) ink. Inkjet head 202c ejects cyan (C) ink. Inkjet head 202k ejects black (K) ink. In this example, inkjet heads 202y-k are an example of coloring material heads that eject colored materials. In this case, the colored materials can be considered, for example, as colored modeling materials for coloring used when forming a colored object. Furthermore, the colors of YMCK are an example of process colors. The inks of the colors of YMCK are an example of colored materials. The inks of each color of YMCK can be considered, for example, as color inks for coloring. The inkjet head 202t is an inkjet head that ejects clear ink. The clear ink can be considered, for example, as ink that is colorless and transparent (T) to visible light. The clear ink can also be considered, for example, as ink to which no coloring material has been intentionally added.

[0030] The multiple ultraviolet light sources 204 are light sources (UV light sources) for curing ink and generate ultraviolet light that cures ultraviolet-curable ink. The ultraviolet light sources 204 can also be considered, for example, as light sources that irradiate ultraviolet light onto the modeling material after it has been ejected by the multiple inkjet heads 202 in the modeling apparatus 12. In this example, the multiple ultraviolet light sources 204 are disposed at one end and the other end of the head unit 102 in the main scanning direction, sandwiching the array of inkjet heads 202 therebetween. Suitable examples of the ultraviolet light sources 204 include UV LEDs (ultraviolet LEDs). Alternatively, metal halide lamps, mercury lamps, and the like can also be used as the ultraviolet light sources 204. The flattening roller 206 is flattening means for flattening the ink layer formed during modeling of the model 50. The flattening roller 206 can also be considered, for example, as a component for flattening a layer formed of the material ejected from the ejection heads. In this example, the flattening roller 206 comes into contact with the surface of the ink layer during the main scanning operation, and flattens the ink layer by removing a portion of the ink before it hardens. By using the head unit 102 configured as described above, it is possible to appropriately form the ink layer that constitutes the model 50, for example. Furthermore, by forming multiple ink layers one on top of the other, it is possible to appropriately form the model 50, for example.

[0031] The specific configuration of the head unit 102 is not limited to the configuration described above and can be modified in various ways. For example, the head unit 102 may further include inkjet heads for colors other than those described above as inkjet heads for coloring. The arrangement of the multiple inkjet heads in the head unit 102 can also be modified in various ways. For example, some inkjet heads may be shifted in position in the sub-scanning direction from the other inkjet heads.

[0032] Next, the configuration of the object 50 formed by the modeling apparatus 12 of this example, and the operation of repairing the object 50 using a repair patch will be described in more detail. FIG. 2 is a diagram illustrating the object 50 formed by the modeling apparatus 12 of this example and the operation of repairing the object 50. FIG. 2(a) is a diagram showing an example of the configuration of the object 50, and shows an example of the configuration of an XY cross section, which is a cross section of the object 50 perpendicular to the stacking direction (Z direction). In this case, the YZ cross section and XZ cross section of the object 50 perpendicular to the X direction and Y direction also have similar regions.

[0033] As explained above, in this example, the modeling device 12 (see FIG. 1) uses the inkjet heads 202y-k (see FIG. 1) and the like to model a modeled object 50 having at least a colored surface. In this case, the coloring of the surface of the modeled object 50 can be considered to mean, for example, coloring at least a part of the area of ​​the modeled object 50 whose color is visible from the outside. In this case, the modeling device 12 models a modeled object 50 including a light reflecting area 152 and a colored area 154, as shown in the figure, for example. In addition, a support layer 52 (see FIG. 1) is formed around the modeled object 50, etc., as necessary.

[0034] The light-reflecting region 152 is a light-reflective region formed inside the colored region 154, and reflects light incident from outside the model 50 through the colored region 154. In this example, the modeling apparatus 12 forms the light-reflecting region 152 inside the model 50 using white ink ejected from the inkjet head 202w (see FIG. 1 ). In this case, the light-reflecting region 152 can be considered to also serve as an internal region, for example. The internal region can be considered to be a region that constitutes the interior of the model 50, for example. In a modified example of the configuration of the model 50, the internal region may be formed as a region separate from the light-reflecting region 152. In this case, the modeling apparatus 12 forms the internal region using, for example, any ink other than the material of the support layer 52. The light-reflecting region 152 is also formed around the internal region. The colored region 154 is a region on the surface of the model 50 that is colored with coloring ink ejected from the inkjet heads 202y to 202k. In this example, the modeling device 12 forms a colored region 154 around (outside) the light reflecting region 152 using coloring inks ejected from the inkjet heads 202y-k and clear ink ejected from the inkjet head 202t (see FIG. 1). In this case, the modeling device 12 expresses various colors by, for example, adjusting the amount of coloring ink ejected at each position. Furthermore, clear ink is used to compensate for variations in the amount of coloring ink that occur due to differences in color. With this configuration, for example, each position in the colored region 154 can be appropriately colored with a desired color. This also makes it possible to appropriately form, for example, a colored object 50.

[0035] Here, after the object 50 is formed by the modeling device 12, various types of damage may occur in the object 50. For example, in the case of an object 50 having a thinner portion than other portions, such as the object 50 configured as shown in FIG. 2(b), damage is more likely to occur in the thinner portion. FIG. 2(b) is a diagram showing an example of how damage occurs in the object 50, illustrating an example of how damage occurs at a damaged portion 60 in an object 50 with a thinner portion. In the diagram, the left side shows an example of the object 50 before damage occurs. The right side shows an example of the object 50 in a state where damage has occurred at the damaged portion 60.

[0036] When such damage occurs to the shaped object 50, a simple repair method could be to connect the damaged area with adhesive, for example. However, in this case, the strength of the repaired area (the damaged area 60 after repair) may be reduced, making it more susceptible to further damage. Furthermore, for example, instead of simply bonding the bonded areas with adhesive, the strength after repair can be increased by reinforcing the damaged area 60 with adhesive tape or the like while it is connected. However, in this case, covering part of the surface of the shaped object 50 with adhesive tape or the like will detract from the appearance of the shaped object 50. In particular, when repairing a colored shaped object 50, covering the colored area with adhesive tape or the like may significantly reduce the design quality.

[0037] In contrast, in this example, a thin-film repair patch 300, such as that shown in FIG. 2(c), is created by the modeling device 12, and the repair patch 300 is used to repair the model 50, thereby suppressing a decrease in strength at the repaired position and also suppressing a decrease in appearance after the repair. FIG. 2(c) shows an example of the configuration of the repair patch 300. In this example, the repair patch 300 is a patch-shaped member (repair patch) that is an example of an attachment member, and is attached to the model 50 when repairing the model 50. The repair patch 300 is also formed by being colored to match the color of the portion of the model 50 that will be covered by the repair patch 300 during repair. With this configuration, for example, by attaching the repair patch 300 to the model 50 and repairing the model 50, the strength of the repaired position can be appropriately increased. Furthermore, by using the repair patch 300 that is colored to match the color of the shaped object 50, for example, the repair patch 300 can be made less noticeable, and deterioration in appearance after repair can be appropriately suppressed. Therefore, according to this example, for example, repair of the shaped object 50 can be more appropriately performed.

[0038] Coloring the repair patch 300 to match the color of the portion of the object 50 that will be covered by the repair patch 300 during repair can be considered, for example, to match the color or pattern of the surface of that portion of the object 50. Also, for convenience of illustration, FIG. 2(b) shows an example of an object 50 with a relatively simple shape. It is also possible to use an object 50 with a more complex shape as the object 50 to be actually repaired. For example, a humanoid figurine representing a person could be used as the object 50. In this case, the figure's limbs, fingers, and other thin parts that are prone to breakage could be considered. Furthermore, repairing the object 50 using the repair patch 300 can be performed, more specifically, as shown in FIG. 3 .

[0039] FIG. 3 is a diagram illustrating in more detail the operation of repairing the model 50 using the repair patch 300. FIGS. 3(a) and 3(b) show an example of the configuration of the repair patch 300. FIG. 3(a) shows an example of the surface condition of the repair patch 300. FIG. 3(b) is a cross-sectional view showing an example of the configuration of the repair patch 300. As explained above, in this example, the repair patch 300 is created using the modeling device 12 (see FIG. 1) in the modeling system 10. Therefore, the repair patch 300 can also be considered, for example, as a thin-film model composed of a small number of ink layers.

[0040] In this example, the repair patch 300 is a flexible film-like body including a colored layer 302 and an adhesive layer 304. In this case, the colored layer 302 is the layer that is colored in the repair patch 300. As described above, in this example, the repair patch 300 is colored to match the color of the portion of the object 50 that will be covered by the repair patch 300 during repair. In this case, the colored layer 302 in the repair patch 300 can be considered to be colored in this manner. In this example, the colored layer 302 is colored in the same manner as or similar to the coloring of the surface of the object 50. More specifically, the coloring of the surface of the object 50 can be performed by, for example, varying the color depending on the position on the surface to create letters, patterns, or the like. In this case, the colored layer 302 is formed by coloring the repair patch 300 to match the color of the portion of the object 50 to be repaired that will be covered by the repair patch 300, as shown in FIG. 3A, so as to create letters or patterns that match the letters or patterns on the surface of the object 50. Similarly to the formation of the colored region 154 (see FIG. 2) of the object 50, clear ink is used when forming the colored layer 302 of the repair patch 300 to compensate for variations in the amount of coloring ink that occur due to differences in color. Therefore, the colored layer 302 of the repair patch 300 can be considered to be formed using, for example, clear ink in addition to colored ink (color ink). With this configuration, the colored layer 302 of the repair patch 300 can be formed by coloring it in the same way as the colored region 154 of the object 50.

[0041] The adhesive layer 304 is a layer for adhering the repair patch 300 to the shaped object 50. In this example, the adhesive layer 304 is a layer that is adhesive at least when the repair patch 300 is attached to the shaped object 50. A method for forming such an adhesive layer 304 will be described in more detail later. In this example, the adhesive layer 304 is a white layer formed using white ink ejected from the inkjet head 202w (see FIG. 1). In this case, the adhesive layer 304 can be considered to also function as a light reflective layer that reflects light incident from the outside through the colored layer 302. Forming such an adhesive layer 304 can also more appropriately express various colors in the colored layer 302, for example. Furthermore, covering the surface of the shaped object 50 with the white adhesive layer 304 can prevent, for example, letters or patterns on the surface of the shaped object 50 from being visible through the repair patch 300. This also makes it possible to appropriately prevent, for example, the characters or patterns on the surface of the shaped object 50 and the characters or patterns drawn on the colored layer 302 of the repair patch 300 from being seen in a double view.

[0042] In this example, when the repair patch 300 is created using the modeling apparatus 12, the colored layer 302 is formed first, and then the adhesive layer 304 is formed thereon. This configuration can appropriately prevent, for example, the sticky adhesive layer 304 from sticking to the modeling table 104 (see FIG. 1 ) of the modeling apparatus 12. In this example, the repair patch 300 can also be considered to be created using the modeling apparatus 12 by additive manufacturing. In this case, the colored layer 302 and the adhesive layer 304 can each be considered to be formed using an ink layer. Furthermore, the colored layer 302 and the adhesive layer 304 being created using the modeling apparatus 12 can be considered to overlap in the stacking direction in which modeling materials overlap in additive manufacturing. The colored layer 302 and the adhesive layer 304 may also be formed using multiple ink layers that overlap in the stacking direction. The thickness of the colored layer 302 in the repair patch 300 is preferably approximately the same as the thickness of the colored region 154 (see FIG. 2) in the shaped object 50. In this case, the thickness of the colored region 154 in the shaped object 50 can be considered to be, for example, the thickness in the normal direction perpendicular to the surface of the shaped object 50. More specifically, the thickness of the colored layer 302 in the repair patch 300 can be considered to be, for example, about 0.5 to 2 times, preferably about 0.7 to 1.5 times, the thickness of the colored region 154 in the shaped object 50. With this configuration, for example, the colored layer 302 of the repair patch 300 can appropriately express colors with quality that matches the colored region 154 in the shaped object 50.

[0043] When repairing a shaped object 50 using such a repair patch 300, the repair patch 300 may be applied as shown in Figures 3(c) and 3(d), for example. Figure 3(c) shows an example of how to apply the repair patch 300 to the shaped object 50 to be repaired. In Figure 3(c), the left side shows the shaped object 50 to be repaired and the repair patch 300 at the start of application of the repair patch 300. The right side shows the shaped object 50 to be repaired and the repair patch 300 at the completion of application of the repair patch 300.

[0044] In the illustrated example, the object 50 is damaged such that a thin portion breaks and the object is split into two. In this case, focusing on one of the two pieces of the object 50, for example, damage resulting in a partial loss can be considered to have occurred. One of the two pieces of the object 50 can also be considered, for example, as the object to be repaired. In this case, the other of the two pieces of the object 50 can be considered, for example, to correspond to a component to be attached to the missing portion of the object to be repaired. From this perspective, hereinafter, at least a portion of the portion of the object 50 that has been damaged in a partial loss and that is to be used for repair will be referred to as the object to be repaired. The object to be repaired can also be considered, for example, to have a configuration corresponding to at least a portion of the object 50 before the damage occurred. A component to be attached to the missing portion of the object to be repaired is referred to as a part for the missing portion. In this case, for example, the portion of the object before the damage, excluding the part for the missing portion, can also be considered to be the object to be repaired.

[0045] More specifically, when damage such as that shown in the figure occurs, one of the two pieces of the object 50 divided as described above can be considered as an example of the object to be repaired. The other of the two pieces of the object 50 can be considered as an example of a part for the missing portion. In this case, for example, the part that is removed from the object to be corrected due to the damage can be considered as the part for the missing portion. Using such a part for the missing portion makes it possible to easily and appropriately prepare the part for the missing portion. Depending on the state of the damage and the required quality of the repair, it may be possible to use a part newly created for repair rather than a part of the object 50 before the damage. For example, depending on the type of damage to the object 50, it may be difficult to use a part of the original object 50 as the part for the missing portion. In such cases, the part for the missing portion is newly created (modeled) using, for example, the modeling device 12 (see FIG. 1 ) used to create the repair patch 300.

[0046] As shown in FIG. 3( c), in this example, when repairing the object 50, the two separate halves of the object 50 are joined at the damaged portion 60, and the repair patch 300 is applied thereto. This operation can be considered, for example, as attaching a part for the missing portion to the object to be repaired and covering at least a portion of the boundary between them with the repair patch 300. The repair patch 300 can be applied, for example, to at least a portion of the surface of the object to be repaired and the part for the missing portion. The adhesive layer 304 of the repair patch 300 can be considered, for example, as functioning as a layer for adhering the repair patch 300 to the object to be repaired and the part for the missing portion. In this case, it is preferable to use an adhesive to adhere one of the two separate halves of the object 50 to the other before applying the repair patch 300. This configuration, for example, can more appropriately increase the strength of the object 50 after repair.

[0047] In this case, the cross-section of the object 50 changes before and after the repair patch 300 is applied, as shown in FIG. 3(d), for example. FIG. 3(d) is a cross-sectional view showing an example of the cross-sectional configuration of the object 50 and the repair patch 300 at the position where the repair patch 300 is applied. In FIG. 3(d), the left-hand diagram shows the cross-section of the object 50 after one of the two halves of the object 50 has been attached to the other, but before the repair patch 300 is applied. In this case, the cross-section of the object 50 has a configuration in which the colored region 154 surrounds the periphery of the light-reflecting region 152, similar to the object 50 before damage occurs. In addition, the right-hand diagram in FIG. 3(d) shows the cross-section of the object 50 and the repair patch 300 after the other of the two halves of the object 50 has been attached to the other, and the repair patch 300 has been applied. In this case, as shown in the figure, at the position where the repair patch 300 is attached, the adhesive layer 304 and the colored layer 302 of the repair patch 300 overlap in this order on the outside of the colored region 154 of the shaped object 50.

[0048] As described above, in this example, the adhesive layer 304 of the repair patch 300 is formed using white ink so as to also function as a light-reflecting layer. In this case, the color of the colored region 154 of the object 50 at the position where the repair patch 300 is attached is concealed by the adhesive layer 304 of the repair patch 300 and is not visible from the outside. Therefore, the adhesive layer 304 of the repair patch 300 can also be considered to function as, for example, a concealing layer that conceals the color of the surface of the object 50. In this case, since the colored layer 302 of the repair patch 300 is located outside the adhesive layer 304, the color of the colored layer 302 can be considered to become, for example, the color of the object 50 after repair. As described above, in this example, the colored layer 302 of the repair patch 300 is formed by coloring it to match the color of the portion of the object 50 that will be covered by the repair patch 300 during repair. Therefore, with this configuration, for example, the color of the repaired object 50 at the position where the repair patch 300 is applied can be made the same as the color before the repair. This also makes it possible to appropriately repair the object 50 using the repair patch 300 while appropriately preventing the appearance of the repaired object 50 from being deteriorated by applying the repair patch 300.

[0049] Next, the operation of repairing the object 50 will be described in more detail. FIG. 4 is a flowchart showing an example of the operation of repairing the object 50, specifically, an example of the operation of repairing a damaged object 50 resulting in partial loss. In the following, the object 50 to be repaired will be referred to as the object to be repaired, as appropriate. In this case, as explained above, the object to be repaired can be considered to be, for example, at least a part of the damaged object 50. In this example, the repair operation is an example of the operation of a method for repairing the object 50 formed by the modeling device 12.

[0050] In this example, the operation of repairing the object to be repaired begins with preparing a part to be attached to the object to be repaired (S102). The operation in step S102 is an example of an operation in the preparation stage. As described above, it is possible to use a part of the object 50 before it is damaged as the part to be attached to the object to be repaired. In this case, the part to be attached to the object to be repaired can be considered, for example, to be a part that has separated from the object 50 due to damage. In this example, in step S102, the parts of the object 50 that have separated due to damage are collected, and one part is treated as the object to be repaired, and the other part is treated as the part to be attached to the object to be repaired. As described above, depending on how the object 50 is damaged, it is also possible to use the modeling device 12 to newly form a part to be attached to the object to be repaired, rather than using a part of the original object 50 as the part to be attached to the object to be repaired. In this case, for example, the operation of forming the part to be attached to the object to be repaired can be considered to be an operation of preparing the part to be attached to the object to be repaired.

[0051] After preparing the part for the missing portion, patch data representing the repair patch 300 is generated (S104), and the modeling device 12 is caused to perform a modeling operation based on the patch data, thereby causing the modeling device 12 to create the repair patch 300 (S106). The operations of steps S104 and S106 are an example of the operation of the attachment member creation stage. In step S104 of this example, the control PC 14 in the modeling system 10 is caused to generate the patch data. The operation of generating the patch data will be described in more detail later. In step S106, the control PC 14 is caused to supply the patch data to the modeling device 12, thereby causing the modeling device 12 to perform a modeling operation based on the patch data.

[0052] Here, having the modeling apparatus 12 create the repair patch 300 can be considered to mean, for example, creating the repair patch 300 using a modeling apparatus 12 capable of forming a colored object by additive manufacturing. As described above, in this example, the repair patch 300 includes a colored layer 302 and an adhesive layer 304. Of these layers, the adhesive layer 304 can be considered to have different properties from the ink layer formed during normal modeling by the modeling apparatus 12. More specifically, as described above, the modeling apparatus 12 of this example uses ultraviolet-curable ink as the modeling material. In this case, the ultraviolet-curable ink can be made adhesive by, for example, irradiating it with ultraviolet light with a quantity of light less than that required for complete curing. Therefore, in this example, the adhesive layer 304 of the repair patch 300 is formed by making the ultraviolet-curable ink adhesive. In this example, in step S106, as described above, the colored layer 302 and the adhesive layer 304 of the repair patch 300 are formed using ink ejected from one of the multiple inkjet heads 202 in the modeling apparatus 12. In this case, the colored layer 302 is formed by irradiating the ink with a sufficient amount of ultraviolet light from the ultraviolet light source 204 in the modeling apparatus 12 to harden the ink until it is no longer sticky. In contrast, when forming the adhesive layer 304 on the colored layer 302, the ultraviolet light source 204 irradiates the ink with a smaller amount of ultraviolet light than when forming the colored layer 302, thereby increasing the viscosity of the white ink used to form the adhesive layer 304 to a sticky state without completely hardening it. With this configuration, for example, the sticky adhesive layer 304 can be appropriately formed using ultraviolet-curable ink, which is a modeling material used in modeling ordinary objects with the modeling apparatus 12. For ultraviolet curable ink, a state in which the viscosity is increased to a state where the ink is sticky without being completely cured can be considered, for example, as a semi-cured (temporarily cured) state.

[0053] After the repair patch 300 is created, the part for the missing portion is attached to the object to be repaired by adhering the part for the missing portion to the object to be repaired using, for example, a known adhesive (S108). The operation in step S108 is an example of an operation in the adhering stage. In this example, the repair patch 300 is attached to the object to be repaired so as to cover at least a portion of the boundary between the object to be repaired and the part for the missing portion, with the part being brought into contact with the object to be repaired by adhering (S110). The operation in step S110 is an example of an operation in the pasting stage. As described above, in this example, the adhesive layer 304 of the repair patch 300 is formed with the ultraviolet-curable ink in a state where the ink is not completely cured. Therefore, in this example, in step S110, after the repair patch 300 is attached to the object to be repaired, ultraviolet light is further irradiated onto the repair patch 300 to cure the ultraviolet-curable ink in the adhesive layer 304. This also allows, for example, the curing of the ultraviolet-curable ink used to form the adhesive layer 304 to be completed, and fixes the repair patch 300 to the object to be repaired. With this configuration, for example, the repair patch 300 can be more appropriately attached to the object to be repaired. This also allows, for example, the object to be repaired to be repaired appropriately.

[0054] Next, the operation of generating patch data in step S104 will be described in more detail. As described above, in this example, the repair patch 300 is formed by coloring it to match the colors of the portions of the object to be repaired and the part for the missing portion that will be covered by the repair patch 300 during repair. In this case, it is also conceivable that the shape of the repair patch 300 is also created to match the shapes of the object to be repaired and the part for the missing portion. Therefore, in this example, the repair patch 300 is created by creating it based on data used during modeling of the object to be repaired. In this case, the time of modeling of the object to be repaired can be considered to be, for example, the time when the object 50 before damage occurred was modeled by the modeling device 12. In this example, the model data used in the modeling device 12 is used as such data. In this case, the model data can be considered to be, for example, data indicating the shape and color of the object 50 to be repaired during modeling. The object data can be thought of as, for example, 3D data that shows the entire object 50 to be repaired. In this example, based on the object data used when modeling the object to be repaired, the control PC 14 in the modeling system 10 generates patch data by the operation shown in Fig. 5.

[0055] FIG. 5 is a flowchart showing an example of an operation for generating patch data. In the operation shown in this flowchart, first, 3D data representing the entire object 50 is acquired (S202). More specifically, in step S202 of this example, the control PC 14 acquires the object data used when the object to be repaired was formed, as 3D data representing the entire object 50, in response to a user instruction or the like. Then, the control PC 14 displays an image representing at least a part of the object to be repaired on the display unit 22, based on the acquired object data (S204). The operation of step S204 is an example of an operation for displaying the object to be repaired to the user. In this case, for example, it is conceivable to display the entire object 50, which will be the object to be repaired, on the display unit 22. Furthermore, for example, in response to a user instruction, a part of the object 50 may be enlarged and displayed on the display unit 22. In this example, it can also be considered that in step S204, the object to be repaired displayed on the display unit 22 is the object 50 before it is damaged.

[0056] In this example, the location of the damaged object to be repaired is determined in response to a user instruction. After displaying the object 50 on the display unit 22 in step S204, the control PC 14 receives from the user a designation (selection) of a repair location, which is a location on the object to be repaired, in response to, for example, a user operation on the operation unit 24 (S206). The operation of step S206 is an example of an operation of a repair location designation stage. The operation of step S206 can also be considered, for example, to be an operation of displaying an image showing at least a portion of the object to be repaired on an image display device and receiving a designation of a repair location from the user. This configuration, for example, makes it possible to appropriately determine a repair location corresponding to the repair patch 300 to be created. After receiving the designation of the repair location, the control PC 14 determines the shape of the repair patch 300 and the color of each location in the colored layer 302 of the repair patch 300, in accordance with the designated repair location (S208). Then, based on the determined shape and color, the control PC 14 generates object data for the repair patch 300 as patch data indicating the repair patch 300 to be created (S210). In this case, the object data generated in step S210 can be considered as, for example, 3D data indicating the shape and color of the repair patch 300.

[0057] With this configuration, for example, the color, shape, and the like of the portion of the object to be repaired that is covered by the repair patch 300 can be appropriately acquired based on the object data representing the object 50. Furthermore, by accepting a repair position designated by the user, for example, the repair position can be appropriately determined. This also makes it possible to appropriately determine, for example, the shape and color of the repair patch 300 that match the repair position of the object 50. Therefore, according to this example, for example, the colored layer 302 of the repair patch 300 can be appropriately colored to match the color of the portion of the object 50 to be repaired that is covered by the repair patch 300. Furthermore, in this example, the control PC 14 supplies the object data for the repair patch 300 to the modeling device 12, causing the modeling device 12 to create the repair patch 300 based on the shape and color determined in step S208. With this configuration, for example, the repair patch 300 that matches the shape, color, and repair position of the object 50 can be appropriately created.

[0058] The operation of creating patch data is not limited to the operation described above and can be modified in various ways. For example, in the operation described above with reference to FIG. 5, the control PC 14 generates patch data representing the repair patch 300 based on the object data used when the object to be repaired was modeled. However, in a modified example of the operation of generating patch data, the patch data may be generated without using such object data. In this case, for example, a 3D scan of the damaged object 50 to be repaired may be performed to directly acquire the shape and color of the object to be repaired. More specifically, in this case, in step S202 of the operation shown in FIG. 5, scan data, which is data obtained by 3D scanning the damaged object 50, is generated as data representing the shape and color of the object to be repaired. In this case, the operation of step S202 can be considered, for example, as an example of the operation of the data generation stage. In this case, the operation from step S204 onward is performed using scan data instead of object data representing the object 50 before damage, thereby generating patch data based on the scan data. Even with this configuration, it is possible to appropriately determine, based on the scan data, the shape of the repair patch 300 and the color of each position of the colored layer 302 of the repair patch 300. Furthermore, based on the determined shape and color, it is possible to appropriately create a repair patch 300 that matches the shape, color, and repair position of the shaped object 50.

[0059] Furthermore, when generating patch data based on scan data, it is preferable to also scan the portion corresponding to the part for the missing portion described above. More specifically, in this case, for example, 3D scanning can be performed with the part for the missing portion attached to the object to be repaired, which corresponds to part of the model 50. This configuration, for example, makes it possible to appropriately acquire the shape and color of the portion of the object to be repaired and the part for the missing portion covered by the repair patch 300. This also makes it possible to more appropriately determine, for example, the shape of the repair patch 300 and the color of each position of the colored layer 302. In this case, it is also possible to perform 3D scanning with the part for the missing portion temporarily attached to the object to be repaired. Various known 3D scanning methods can be used, for example. In this case, it is also possible to perform 3D scanning using multiple photographs taken from different angles using a smartphone or the like. With this configuration, for example, 3D scanning can be easily performed without using expensive dedicated equipment. Furthermore, generation of patch data can be performed by a computer other than the control PC 14, for example. In this case, the control PC 14 supplies patch data received from the outside to the modeling apparatus 12, thereby causing the modeling apparatus 12 to create the repair patch 300.

[0060] Furthermore, in the operation of creating patch data, the repair position may be determined based on, for example, object data representing the object 50 before damage and the state of the damaged object 50. More specifically, in this case, the position where the damage has occurred (the damage position) may be detected based on the object data used when the object 50 to be repaired was created and an image (e.g., a photograph) representing the damaged object 50. In this case, a computer (e.g., the control PC 14) that executes the operation of creating patch data may determine candidate repair positions based on the detected damage positions and display them on the display unit 22. Then, instructions to change or correct the repair positions may be received from the user as needed, and the repair positions may be determined based on the received instructions. This configuration, for example, may make it possible to more easily and appropriately determine the repair positions.

[0061] Furthermore, the configuration of the repair patch 300 is not limited to the configuration described above and can be modified in various ways. FIG. 6 illustrates a modified configuration of the repair patch 300. FIGS. 6(a) and 6(b) illustrate modified configurations of the repair patch 300. Except as described below, components in FIG. 6 that are designated by the same reference numerals as those in FIGS. 1 to 5 may have the same or similar features as those in FIGS. 1 to 5. The above description of the configuration of the repair patch 300 mainly focuses on a configuration in which the adhesive layer 304 of the repair patch 300 is formed using white ink, so that the adhesive layer 304 also serves as a light-reflecting layer. However, in a modified configuration of the repair patch 300, the adhesive layer 304 of the repair patch 300 may be formed in a color other than white using ink other than white. In this case, for example, it is conceivable to form the colorless and transparent adhesive layer 304 using clear ink. In this case, it is also possible to create a repair patch 300 that further includes a light-reflecting layer 306 in addition to the colored layer 302 and adhesive layer 304, as shown in FIG. 6( a), for example. More specifically, in this case, it is possible to form a white light-reflecting layer 306 between the colored layer 302 and adhesive layer 304 using white ink. In this case, it is also possible to form only the adhesive layer 304 of the layers in the repair patch 300 to be adhesive, and to form the colored layer 302 and the light-reflecting layer 306 in a non-adhesive state by irradiating them with a sufficient amount of ultraviolet light. Even with this configuration, it is possible to appropriately create a repair patch 300 that is colored in the same way as the shaped object 50.

[0062] 1 to 5, for the sake of convenience, examples of the shape of the repair patch 300 are shown with a simple shape. However, as explained above, it is conceivable that the shape of the repair patch 300 is made to match the repair position on the shaped object 50. Therefore, it is conceivable that the shape of the repair patch 300 is made to match the repair position, such as the shape shown in FIG. 6(b). In this case, it is also conceivable to create a repair patch 300 with a more complex shape as needed.

[0063] The above description has mainly focused on a method for forming the adhesive layer 304 of the repair patch 300 using an ultraviolet-curable ink that is used as a modeling material when modeling a normal object. However, a variation in the method for forming the adhesive layer 304 may involve, for example, forming the adhesive layer 304 with an adhesive material that is not used as a modeling material when modeling a normal object. In this case, the material that is not used as a modeling material when modeling a normal object may be considered to be, for example, a material that is not used when modeling an object identical to the object to be repaired. More specifically, the adhesive material may be considered to be, for example, a material that is used for the adhesive layer 304 of the repair patch 300 but is not used when forming the same regions as the light-reflecting region 152 and the colored region 154 (see FIG. 2 ) of the object 50 to be repaired. In this case, the repair patch 300 may be created using a modeling device 12 that is configured to dispense an adhesive material in addition to the modeling material used when modeling a normal object. More specifically, in this case, it is conceivable to create the repair patch 300 using a modeling apparatus 12 equipped with a head unit 102 having the configuration shown in FIG. 6(c), for example.

[0064] FIG. 6(c) shows a modified configuration of the head unit 102 in the modeling apparatus 12 (see FIG. 1). In this modified example, the head unit 102 further includes an inkjet head 208 as a plurality of inkjet heads in addition to the inkjet heads 202s to 202t in the head unit 102 configured as shown in FIG. 1(c). The head unit 102 also includes ultraviolet light sources 204 for the inkjet head 208, on one side and the other side of the inkjet head 208 in the main scanning direction. In this case, the modeling apparatus 12 can be considered to have a configuration in which, for example, when modeling an object that is the same as or similar to the object 50 to be repaired, the inkjet head 208 is not used, and when creating a repair patch 300, the inkjet head 208 is used.

[0065] In this modification, the inkjet head 208 is an example of an adhesive material head that ejects an adhesive material used as a material for the adhesive layer 304. It is possible to form the repair patch 300 having a separate light-reflecting layer 306 and adhesive layer 304, as shown in FIG. 6 . More specifically, when forming the repair patch 300, the modeling device 12 forms the colored layer 302 using, for example, colored inks ejected from the inkjet heads 202y to 202k and clear ink ejected from the inkjet head 202t. Furthermore, the light-reflecting layer 306 is formed on the colored layer 302 using white ink ejected from the inkjet head 202w. Then, the adhesive layer 304 is formed on the light-reflecting layer 306 using an adhesive material ejected from the inkjet head 208. Even with this configuration, it is possible to appropriately create the repair patch 300 used for repairing the shaped object 50, for example.

[0066] In this modification, the adhesive material ejected from the inkjet head 208 may be, for example, an ink that adheres to the ejected position. Furthermore, such an adhesive material may be, for example, an ultraviolet-curable ink that maintains its adhesiveness even after sufficient ultraviolet irradiation and curing are complete. More specifically, such an adhesive material may be a liquid that is the same as or similar to a known ultraviolet-curable ink (primer ink) used for forming a base. Such a primer ink may be, for example, a known primer ink (e.g., PR-200 ink) sold by Mimaki Engineering Co., Ltd. Furthermore, when a repair patch 300 including such an adhesive layer 304 is used, the adhesive layer 304 can be considered to be in a fully cured state rather than a semi-cured state upon completion of the repair patch 300. Therefore, in this case, it is possible to complete the attachment of the repair patch 300 to the object to be repaired without further ultraviolet irradiation during repair. Even with this configuration, the repair patch 300 can be appropriately attached to the object to be repaired. In a further modified example of the configuration of the modeling apparatus 12, it is possible to use, for example, an adhesive material that is not UV-curable as an adhesive material that is not used as a modeling material when modeling a normal object.

[0067] Next, supplementary explanations will be provided regarding the above-described configurations. For ease of explanation, the following will refer to the configuration of this example, including various modified examples. As described above, in this example, at least a portion of a damaged object is used as the object to be repaired, and the object is repaired. In this case, by attaching a repair patch 300 created using the modeling device 12 to at least a portion of the repair position on the object, it is possible to appropriately increase the strength of the object after repair, for example. Furthermore, by using a repair patch 300 including at least a colored layer 302 and an adhesive layer 304, it is possible to easily and appropriately create a repair patch 300 that is appropriately colored and adheres to the object using the modeling device 12. Furthermore, by coloring the colored layer 302 of the repair patch 300 to match the color of the portion of the object to be repaired that will be covered by the repair patch 300, it is possible to appropriately prevent the repair patch 300 from being excessively conspicuous on the repaired object, for example.

[0068] In this regard, if the repair patch 300 is created using the modeling device 12 capable of modeling a modeled object, it may seem appropriate to create a new modeled object of the same shape and color as the damaged model, rather than repairing it using the repair patch 300. However, depending on the purpose of the modeled object, repairing it may be preferable to create a new modeled object rather than creating a new one. More specifically, for example, creating a new model may require a large amount of ink as a modeling material, which may result in high costs. Furthermore, if a modeled object that has undergone additional processing after being modeled using the modeling device 12 is damaged, it may not be possible to create a model identical to the damaged object simply by modeling it using the modeling device 12. In contrast, according to this example, the use of the repair patch 300 allows the modeled object to be repaired appropriately and at low cost. Furthermore, in this case, the repair of the modeled object performed in this example can be considered a method particularly suitable for performing simple repairs that are inexpensive, for example.

[0069] As described above, in this example, the repair patch 300 is created using a modeling device 12 capable of modeling an object by additive manufacturing. In this case, for example, it is possible to create the repair patch 300 using the modeling device 12 (the same modeling device) that modeled the object to be repaired. The modeling device 12 used to create the repair patch 300 may be a different model from the model that modeled the object to be repaired. In this case, it is preferable to use a modeling device 12 of the same model as the model that modeled the object, or a compatible model. This configuration makes it possible to more appropriately create a repair patch 300 that is colored in the same way as the object to be repaired. In this case, it is preferable to make the thickness of each ink layer layered by additive manufacturing the same when the object is modeled and when the repair patch 300 is created. This configuration makes it possible to more appropriately create a repair patch 300 that is colored to match the object. Depending on the quality required for the repair, the repair patch 300 may be created using a modeling device 12 that is not the same model as or compatible with the modeling device that created the object. Even in such a case, the object can be appropriately repaired by using a repair patch 300 that is colored to match the surface of the object. [Industrial Applicability]

[0070] The present invention can be suitably used, for example, as a method for repairing a shaped object. [Explanation of symbols]

[0071] 10···Modeling system, 102···Head unit, 104···Modeling table, 106···Scanning drive unit, 110···Control unit, 12···Modeling device, 14···Control PC, 152···Light reflective area, 154···Coloring area, 202···Inkjet head, 204···Ultraviolet light source, 206···Flattening roller, 208···Inkjet head, 22···Display unit, 24···Operation unit, 26···Main body unit, 300···Repair patch, 302···Coloring layer, 304···Adhesive layer, 306···Light reflective layer, 50···Modeled object, 52···Support layer, 60···Damaged area

Claims

1. A method for repairing a modeled object formed by a modeling apparatus, comprising: a preparation step of preparing a part for the missing portion, which is a member to be attached to the missing portion of the object to be repaired, which is the object that has been damaged and has lost a portion; a repair position designation step of receiving designation of a repair position that is a position to be repaired in the object to be repaired; an attachment member preparation step of preparing an attachment member to be attached to at least a part of the surface of the object to be repaired and the part for missing portion; an attaching step of attaching the attaching member so as to cover at least a part of a boundary between the object to be repaired and the part for missing portion while the object to be repaired and the part for missing portion are in contact with each other; Equipped with At least a part of the surface of the object to be repaired is colored, In the repair position designation step, an image showing at least a part of the object to be repaired is displayed on an image display device, and designation of the repair position is accepted; In the attaching member creating step, using a modeling device capable of forming the colored modeled object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: the colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; and in the step of creating the attachment member, determining the shape of the attachment member and the color of each position in the colored layer in accordance with the repair position specified in the step of specifying the repair position, and creating the attachment member based on the determined shape and color.

2. A method for repairing a molded object formed by a molding apparatus, comprising: a preparation step of preparing a part for the missing portion, which is a member to be attached to the missing portion of the object to be repaired, which is the object that has been damaged and has lost a portion; an attachment member preparation step of preparing an attachment member to be attached to at least a part of the surface of the object to be repaired and the part for missing portion; an attaching step of attaching the attaching member so as to cover at least a part of a boundary between the object to be repaired and the part for missing portion while the object to be repaired and the part for missing portion are in contact with each other; Equipped with At least a part of the surface of the object to be repaired is colored, In the attaching member creating step, using a modeling device capable of forming the colored modeled object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: the colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; and in the attaching member creating step, determining a color of each position in the colored layer of the attaching member based on object data that is data indicating the shape and color of the object to be repaired and that was used when the object to be repaired was created, and creating the attaching member based on the determined colors.

3. A method for repairing a molded object formed by a molding device, comprising: a preparation step of preparing a part for the missing portion, which is a member to be attached to the missing portion of the object to be repaired, which is the object that has been damaged and has lost a portion; a data generation step of generating scan data obtained by 3D scanning the object to be repaired; an attachment member preparation step of preparing an attachment member to be attached to at least a part of the surface of the object to be repaired and the part for missing portion; an attaching step of attaching the attaching member so as to cover at least a part of a boundary between the object to be repaired and the part for missing portion while the object to be repaired and the part for missing portion are in contact with each other; Equipped with At least a part of the surface of the object to be repaired is colored, In the attaching member creating step, using a modeling device capable of forming the colored modeled object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: the colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; and in the attachment member creation step, determining the color of each position in the colored layer of the attachment member based on the scan data generated in the data generation step, and creating the attachment member based on the determined color.

4. A method for repairing a molded object formed by a molding device, comprising: a preparation step of preparing a part for the missing portion, which is a member to be attached to the missing portion of the object to be repaired, which is the object that has been damaged and has lost a portion; an attachment member preparation step of preparing an attachment member to be attached to at least a part of the surface of the object to be repaired and the part for missing portion; an attaching step of attaching the attaching member so as to cover at least a part of a boundary between the object to be repaired and the part for missing portion while the object to be repaired and the part for missing portion are in contact with each other; Equipped with At least a part of the surface of the object to be repaired is colored, In the attaching member creating step, using a modeling device capable of forming the colored modeled object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: the colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; The object to be repaired is a colored region on the surface of the object to be repaired; a light-reflecting area formed inside the colored area to be light-reflective; Equipped with the modeling device used in the attaching member creating step is a device that dispenses an ultraviolet curable material as a modeling material, a plurality of ejection heads each ejecting the modeling material; an ultraviolet light source that irradiates ultraviolet light onto the modeling material after it has been discharged; Equipped with The plurality of ejection heads include at least a coloring material head that ejects a colored material that is the colored modeling material for coloring; a light-reflective material head that ejects the light-reflective material, which is the light-reflective modeling material; Equipped with In the attaching member preparation step, forming the colored layer using at least the colored material ejected from the coloring material head; forming the adhesive layer using the modeling material discharged from any one of the plurality of discharge heads, and increasing the viscosity of the modeling material to a state where it is tacky by irradiating ultraviolet light from the ultraviolet light source onto the modeling material during the formation of the adhesive layer; a method for repairing a shaped object, characterized in that, in the attaching step, after attaching the attaching member to the shaped object to be repaired, the attaching member is irradiated with ultraviolet light to harden the shaping material in the adhesive layer.

5. A method for repairing a molded object formed by a molding device, comprising: a preparation step of preparing a part for the missing portion, which is a member to be attached to the missing portion of the object to be repaired, which is the object that has been damaged and has lost a portion; an attachment member preparation step of preparing an attachment member to be attached to at least a part of the surface of the object to be repaired and the part for missing portion; an attaching step of attaching the attaching member so as to cover at least a part of a boundary between the object to be repaired and the part for missing portion while the object to be repaired and the part for missing portion are in contact with each other; Equipped with At least a part of the surface of the object to be repaired is colored, In the attaching member creating step, using a modeling device capable of forming the colored modeled object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: the colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; The object to be repaired is a colored region on the surface of the object to be repaired; a light-reflecting area formed inside the colored area to be light-reflective; Equipped with the modeling device used in the attaching member creating step includes a plurality of ejection heads each ejecting a modeling material, The plurality of ejection heads include at least a coloring material head that ejects a colored material that is the colored modeling material for coloring; a light-reflective material head that ejects a light-reflective material that is the light-reflective modeling material; an adhesive material head that dispenses the adhesive material, which is the material of the adhesive layer of the attachment member and is not used when forming the same regions as the colored regions and the light reflecting regions of the object to be repaired; Equipped with In the attaching member preparation step, forming the colored layer using at least the colored material ejected from the coloring material head; A method for repairing a shaped object, comprising forming the adhesive layer using the adhesive material discharged from the adhesive material head.

6. A modeling system that models an attachment member that is to be attached to a repair-target object, which is a model that has been damaged and has a portion missing, when repairing the repair-target object, comprising: a modeling device capable of forming the colored object by an additive manufacturing method; a control device that controls the operation of the molding device; Equipped with the affixing member is a member that is attached to at least a portion of the surface of the object to be repaired and the part for missing portion, which is a member that is attached to a missing portion of the object to be repaired, so as to cover at least a portion of the boundary between the object to be repaired and the part for missing portion, with the part for missing portion being in contact with the object to be repaired; At least a part of the surface of the object to be repaired is colored, The attachment member is an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; Equipped with the control device supplies, to the modeling device, data indicating the affixing member having the colored layer that is colored to match the color of the portion of the object to be repaired that is covered with the affixing member, thereby causing the modeling device to model the object that will become the affixing member; and displaying an image showing at least a portion of the object to be repaired on an image display device, accepting specification of repair positions on the object to be repaired, and determining the shape of the attachment member and the color of each position in the colored layer according to the specified repair positions, and causing the modeling device to model the object to become the attachment member based on the determined shape and color.

7. A method for manufacturing an attachment member that is a member to be attached to a repair-target object, which is a damaged object that is partially missing, when repairing the repair-target object, the repair target object being a damaged object, the method comprising: the affixing member is a member that is attached to at least a portion of the surface of the object to be repaired and the part for missing portion, which is a member that is attached to a missing portion of the object to be repaired, so as to cover at least a portion of the boundary between the object to be repaired and the part for missing portion, with the part for missing portion being in contact with the object to be repaired; At least a part of the surface of the object to be repaired is colored, Using a modeling device capable of manufacturing the colored object by an additive manufacturing method, an adhesive layer that is a layer for adhering the attachment member to the object to be repaired and the part for missing portion; A colored layer, which is a colored layer; and creating the attachment member comprising: The colored layer is formed by coloring it to match the color of the portion of the object to be repaired that is to be covered by the affixing member; and displaying an image showing at least a part of the object to be repaired on an image display device, accepting specification of repair positions on the object to be repaired, and determining the shape of the attachment member and the color of each position on the colored layer in accordance with the specified repair positions, thereby creating the attachment member based on the determined shape and color.

Images