Roughness Shape Data Correction for Resin Texture Reproduction
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Solution Overview
Problem
Image forming apparatuses struggle to reproduce sharp or high-elevation roughness shapes due to surface tension and wetting spreading characteristics of curable resin materials, resulting in loss of texture and contrast in the final output.
Innovation Solution
An image processing apparatus that corrects roughness shape data based on output characteristics of the image forming apparatus, including frequency and amplitude corrections, to ensure the reproduction of desired textures by adjusting the data to fall within the apparatus's output possible range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the image forming apparatus outputs resin printing material based on roughness shape data specifying a sharp roughness shape, then the sharp roughness shape is intended to be reproduced, but the shape changes before the resin printing material solidifies due to surface tension and wetting spreading characteristics, resulting in inability to reproduce the sharp roughness shape
Solution Approach 1:
The system performs preliminary correction on the roughness shape data before outputting to the image forming apparatus. By pre-adjusting the shape data to account for expected material deformation, the final reproduced shape achieves the desired accuracy despite the resin's surface tension and wetting characteristics causing shape changes during solidification.
Solution Approach 2:
The system modifies parameters in the roughness shape data (such as elevation values, slope angles, and feature dimensions) to compensate for the resin material's physical characteristics. By changing these parameters in advance, the system ensures that the final reproduced roughness shape matches the intended design despite material deformation during the solidification process.
2Manufacturing precision
If the image forming apparatus outputs resin printing material based on roughness shape data specifying a shape with large difference of elevation in roughness, then the desired texture is intended to be reproduced, but the resin printing material for forming a convex portion spreads up to a concave portion, resulting in inability to maintain the difference of elevation
Solution Approach 1:
The system performs preliminary correction on the roughness shape data to anticipate and compensate for resin material spreading. By pre-adjusting the elevation differences and modifying the shape characteristics before output, the system ensures that the final reproduced texture maintains the intended elevation variations despite the resin spreading from convex to concave portions during solidification.
Solution Approach 2:
The system applies preliminary anti-action by correcting the roughness shape data in advance to counteract the expected spreading effect. The correction process reduces elevation differences and adjusts shape parameters beforehand, creating a compensatory effect that maintains the desired texture and elevation contrast in the final output despite the resin's natural spreading tendency.
3Manufacturing precision
If roughness shape data is corrected to be within the output possible range of the image forming apparatus, then the desired texture can be reproduced, but the original roughness shape data may be modified beyond recognition
Solution Approach 1:
The system applies targeted parameter changes to the roughness shape data, modifying only specific parameters (such as elevation values, slope angles, or feature dimensions) that are necessary to bring the data within the output possible range. This selective approach preserves the essential characteristics and overall structure of the original roughness shape while making minimal necessary adjustments to achieve faithful texture reproduction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the stable reproduction of textures with improved reproducibility and extended range of compatible roughness shape data, maintaining the desired texture even when the original data exceeds the apparatus's output limits.
Implementation Method 1
the curable resin printing material has the surface tension and wetting spreading characteristics
Implementation Method 2
the curable resin printing material has the surface tension and wetting spreading characteristics
Data Source
AI summary
The image processing apparatus in the present invention is an image processing apparatus that supplies roughness shape data to an image forming apparatus that forms a roughness shape based on a roughness shape of an object to be reproduced. The image processing apparatus includes: an input reception unit configured to receive an input of information representing the roughness shape of the object to be reproduced; an acquisition unit configured to acquire output characteristics relating to a roughness shape that the image forming apparatus can output; and a generation unit configured to generate roughness shape data that is supplied to the image forming apparatus based on the information representing the roughness shape of the object to be reproduced and the output characteristics.