JP7750760B2 - Method for adjusting a molding device, molding system, and method for manufacturing a confirmation molded object - Google Patents

Description

The present invention relates to a method for adjusting a modeling device, a modeling system, and a method for manufacturing a confirmation model.

Conventionally, there are known modeling devices (3D printers) that use inkjet heads to create objects (see, for example, Patent Document 1). In such modeling devices, for example, an object is created using a layered modeling method by stacking multiple layers of ink formed by the inkjet head.

JP 2015-071282 A

When using a modeling device to create a modeled object, any imperfections in the device's operation can make it difficult to achieve high-quality results. In the case of inkjet printers that print two-dimensional images, for example, a commonly used method is to print a specified test pattern and then adjust the inkjet head. Therefore, it is conceivable to perform adjustments to the ejection head of a modeling device similar to those performed on an inkjet printer. In this case, it is also conceivable to confirm the ejection characteristics of the ejection head by ejecting modeling material from the ejection head of the modeling device onto a sheet-like member. However, when creating a modeled object using a modeling device, it may be difficult to create a modeled object with high precision simply by performing adjustments similar to those performed on an inkjet printer. Therefore, a more appropriate method for adjusting the modeling device is desirable. Therefore, the present invention aims to provide a method for adjusting a modeling device, a modeling system, and a method for manufacturing a confirmation object that can solve the above problems.

The inventors of the present application conducted extensive research into methods for adjusting a modeling device and came up with the idea of creating a confirmation object, a model used to confirm the operation of the modeling device. In this case, by checking the condition of the confirmation object and adjusting the modeling device based on the results of that check, the modeling device can be appropriately adjusted to meet the quality requirements of the model. Furthermore, a modeling device may, for example, create a model by stacking layers formed with the modeling material. In this case, the modeling device may flatten the layers formed with the modeling material using, for example, a flattening roller. Furthermore, in this case, if the flattening roller is misaligned or tilted, the layers may not be properly flattened, which has a significant impact on the quality of the model. Therefore, the inventors of the present application came up with the idea of adjusting the modeling device by having the modeling device create a confirmation object having a portion for checking the operation of flattening the layers using the flattening roller. This configuration allows the modeling device to be appropriately adjusted, for example, using a method suited to the configuration of the modeling device.

Furthermore, through further intensive research, the inventors of the present application discovered the features necessary to achieve these effects, and arrived at the present invention. To solve the above-mentioned problems, the present invention provides a method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, the method comprising: a modeling step of forming a confirmation object, which is the object used to confirm the operation of the modeling device; a confirmation step of confirming the condition of the confirmation object formed in the modeling step; and an adjustment step of adjusting the modeling device based on the condition of the confirmation object confirmed in the confirmation step. The modeling device comprises a discharge head that discharges the modeling material and a flattening roller that flattenes the layer formed of the material discharged from the discharge head, and in the modeling step, the modeling device is caused to form the confirmation object having a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling device.

With this configuration, for example, the flattening operation by the flattening roller can be confirmed by checking the state of the flattening operation checking portion of the confirmation object. In this case, it is possible to check, for example, whether flattening is being performed properly with respect to the flattening operation by the flattening roller. Furthermore, if flattening is not being performed properly, it is also possible to check, for example, the degree of deviation or tilt of the flattening roller based on the state of the flattening operation checking portion. Furthermore, in this case, by adjusting the modeling device based on the confirmed state of the confirmation object during the adjustment stage, it is possible to appropriately adjust the modeling device, for example. More specifically, in this case, it is possible to adjust the flattening roller based on the results of checking the flattening operation checking portion. With this configuration, it is possible to appropriately adjust the modeling device, for example, using a method appropriate for the configuration of the modeling device.

Furthermore, when a model is formed by stacking layers as in this configuration, it is conceivable that steps will be formed in the curved surface portions depending on the modeling resolution. The appearance of such steps may change depending on, for example, how the flattening is performed by the flattening roller. More specifically, for example, if the flattening roller is not properly adjusted, the appearance of such parts may differ greatly from when it is properly adjusted. Therefore, in this configuration, it is conceivable that the part used to check the flattening operation includes a part that includes a curved surface portion that is expressed by steps that occur depending on the modeling resolution of the modeling device. This configuration, for example, makes it possible to more appropriately check the flattening operation of the flattening roller. This also makes it possible, for example, to more appropriately adjust the flattening roller.

In addition, in this configuration, the modeling device is equipped with a colored material head, which is, for example, a discharge head that discharges a colored material. The colored material can be considered, for example, as a colored material used when forming a colored object. In this case, it is conceivable that, during the modeling stage, at least a portion of the confirmation object is formed using, for example, the colored material discharged from the colored material head. With this configuration, by coloring at least a portion of the confirmation object, it is possible, for example, to more easily and appropriately check the state of the confirmation object. Furthermore, by coloring at least a portion of the confirmation object, it is also possible, for example, to check the state of the colored material head.

The confirmation object may be, for example, an object having portions other than the curved surface portion described above. More specifically, in this configuration, the modeling device further includes, for example, a light-reflective material head, which is a discharge head that discharges a light-reflective material. In this case, during the modeling stage, the modeling device is caused to model a confirmation object having, on its upper surface, a solid colored portion, which is a portion in which at least a portion of a predetermined area is colored by filling it in with a colored material. In this case, the periphery of the solid colored portion on the upper surface is formed, for example, using a light-reflective material in a color different from that of the solid colored portion.

In this case, if the flattening roller is not adjusted properly, for example, the colored material dispensed to form the solid colored portion may be dragged by the flattening roller, resulting in unintended coloring outside the solid colored portion. Therefore, this configuration allows for more appropriate confirmation of the flattening operation by the flattening roller. Furthermore, in this case, the solid colored portion can be considered to be part of the flattening operation confirmation portion of the confirmation object. Furthermore, the flattening operation confirmation portion can be considered to include the solid colored portion in addition to the curved portion described above. Furthermore, when forming such a solid colored portion, it is possible to further confirm things other than the flattening operation by the flattening roller. In this case, for example, it is possible to confirm the filling operation by the colored material head based on the state of the solid colored portion. It is also possible to confirm the state of the colored material head and the light-reflective material head based on the state of the solid colored portion and its surroundings.

When forming a confirmation object having a solid colored portion, it is also possible to, for example, leave a portion of the solid colored portion blank. This configuration allows for more appropriate confirmation of the state of the modeling device by, for example, checking whether the blank portion is properly formed. In this case, it is also possible to form a solid colored portion including blank characters. Blank characters can be considered to be characters rendered in the color of a light-reflective material within the solid colored portion. More specifically, in this case, it is also possible to form a portion in which, for example, multiple different sizes of characters are rendered in the color of a light-reflective material, with the remaining portions being filled in with a colored material. This configuration allows for more appropriate confirmation of the state of the modeling device. Furthermore, by displaying blank characters of multiple sizes in the solid printing portion, it is possible to more appropriately confirm, for example, whether the modeling is being performed with the desired quality. During the modeling stage, the modeling device may also form a confirmation object having a solid colored portion on the underside, for example. In this case, the confirmation object has, for example, a light-reflective area formed using a light-reflective material between the solid colored portion on the upper surface and the solid colored portion on the lower surface. This configuration makes it possible to more appropriately check the state of the modeling device, for example.

When creating a colored object, it is possible to use a coloring material to draw letters on the surface of the object. In this case, if the drawn letters are distorted, it is likely to give the impression that the object is of low quality. Therefore, when adjusting the modeling device, it is preferable to confirm, for example, that the letters can be drawn appropriately with the required precision. In this case, it is possible to have the modeling device create a confirmation object during the modeling stage that further includes a character confirmation portion for checking the characters drawn using a colored material. In this case, it is also possible to form the character confirmation portion as a portion in which letters of different sizes are drawn using a colored material within an area where the surrounding area of the letters is the color of a light-reflective material. This configuration makes it possible, for example, to properly check how the letters are drawn during modeling. Furthermore, by expressing letters of different sizes in the character confirmation portion, it is possible to more properly check, for example, whether the object is being modeled with the desired quality.

In this configuration, the modeling device includes, for example, multiple colored material heads, each of which dispenses a different colored material. In this case, it is possible to use a confirmation object that includes a portion formed using multiple colored materials. Such a portion may be a three-dimensional portion, such as a stepped portion. More specifically, in this case, during the modeling stage, the modeling device is caused to form a confirmation object that further includes a stepped portion formed by overlapping multiple layers with different edge positions. In this case, at least the upper surface of the stepped portion is colored using multiple colored materials dispensed from the multiple colored material heads. This configuration makes it possible to appropriately check, for example, how the three-dimensional portion is colored. Furthermore, by using multiple colored materials to form a three-dimensional portion colored in various colors, it is possible to more closely check, for example, the flattening operation of the flattening roller.

The confirmation object may further include a portion for checking various conditions other than those described above. For example, during the modeling stage, the modeling device may be configured to create a confirmation object that further includes a line checking portion for checking lines expressed using a colored material. In this case, the line checking portion may include, for example, a portion that expresses multiple types of lines with different line widths. Furthermore, the lines of each line width may include, for example, multiple lines extending in multiple different directions. This configuration makes it possible to appropriately check, for example, whether the modeling device is adjusted to a state where it can draw lines of various widths and directions that will serve as elements of an image to be drawn on the surface of the object. During the modeling stage, the modeling device may be configured to create a confirmation object with a through-hole that penetrates from the top to the bottom. This configuration makes it possible to appropriately check, for example, whether the modeling device is adjusted to a state where it can create an object with a through-hole.

The present invention may also be configured to use a modeling system or a method for manufacturing a confirmation object having the same characteristics as those described above. Furthermore, when forming an object using the modeling system, the modeling device may flatten the layers using a flattening roller that has been adjusted based on the results of checking the state of the confirmation object. In these cases, the same effects as those described above can be obtained.

According to the present invention, for example, adjustment of the modeling device can be performed appropriately using a method suited to the configuration of the modeling device.

1A and 1B are diagrams illustrating a modeling system 10 that executes a method for adjusting a modeling device 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. Fig. 1C shows an example of the configuration of a head unit 102. 2A and 2B are diagrams illustrating a model 50 manufactured by the modeling apparatus 12 of this embodiment. Fig. 2A shows an example of the configuration of the model 50. Fig. 2B shows an example of an aspect in which a plurality of layers 172 formed by additive manufacturing are stacked on top of each other. 3A and 3B are diagrams illustrating a confirmation object 300 used in this example. Fig. 3A is a top view showing an example of the configuration of the confirmation object 300. Fig. 3B is a side view of the confirmation object 300. Fig. 3C is a bottom view of the confirmation object 300. 4A and 4B are diagrams illustrating in more detail the curved surface portion 304 and the step portion 306 of the confirmation object 300. Fig. 4A shows an example of the configuration of the curved surface portion 304. Fig. 4B shows an example of the configuration of the step portion 306. Fig. 4C shows an enlarged schematic view of the shape of the slope 342 of the step portion 306. 10 is a flowchart illustrating an example of an operation for adjusting the molding device 12.

Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 is a diagram illustrating a modeling system 10 that executes a method for adjusting a modeling device according to one embodiment of the present invention. FIG. 1(a) shows an example of the configuration of the modeling system 10. In this example, the modeling system 10 is a modeling system that models a three-dimensional object, and includes a modeling device 12 and a control PC 14. The object modeled by the modeling system 10 can be considered to be, for example, a three-dimensional structure.

The modeling device 12 is a device that executes modeling of objects, and models the objects in accordance with the control of the control PC 14. In this example, the modeling device 12 is a full-color modeling device that can model objects colored in full color. It receives object data representing the object to be modeled from the control PC 14, and models the object based on the object data. The control PC 14 is a computer (host PC) that controls the operation of the modeling device 12, and controls the modeling operation of the modeling device 12 by supplying the object data to the modeling device 12. In this example, the control PC 14 also supplies object data representing an object whose surface is colored so that the color can be seen from outside to the modeling device 12.

In this example, the modeling system 10 is composed of multiple devices, namely, modeling devices 12 and a control PC 14. In a modified version of the modeling system 10, the modeling system 10 may be composed of a single device. In this case, for example, the modeling system 10 may be composed of a single modeling device 12 that includes the functions of the control PC 14. Furthermore, the modeling system 10 may further include devices other than the modeling devices 12 and the control PC 14.

Next, the specific configuration of the modeling device 12 will be described. FIG. 1(b) shows an example of the configuration of the main parts of the modeling device 12. In this example, the modeling device 12 is a modeling device (3D printer) that uses additive manufacturing to model a three-dimensional object 50, and includes a head unit 102, a modeling table 104, a scan driver 106, and a controller 110. In this case, additive manufacturing can be considered, for example, as a method of forming the object 50 by stacking layers formed of a modeling material. Furthermore, except as described below, the modeling device 12 may have the same or similar configuration as a known modeling device that performs modeling by using an inkjet head to eject droplets of material for the object 50. Furthermore, in addition to the components shown in the figure, the modeling device 12 may further include various components necessary for, for example, modeling the object 50.

The head unit 102 is configured to eject the material for the object 50. In this example, ink is used as the material for the object 50. The ink can be considered, for example, a functional liquid. The ink can also be considered, for example, a liquid ejected from an inkjet head. In this example, the head unit 102 ejects ink that hardens under specified conditions from multiple inkjet heads as the material for the object 50. The ink is then cured after impact, forming each layer that makes up the object 50 and creating the object using an additive manufacturing method. In this example, ultraviolet-curable ink (UV ink) that hardens from a liquid state when irradiated with ultraviolet light is used as this ink. In addition to the material for the object 50, the head unit 102 also ejects the material for 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 thought of as, for example, a laminated structure that supports at least a portion 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 complete.

The modeling table 104 is a platform-like member that supports the object 50 being modeled. It is disposed opposite 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 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.

The scan driver 106 is a driver that causes the head unit 102 to perform a scanning operation, moving relative to the object 50 being modeled. In this example, moving relative to the object 50 being modeled can be considered, for example, to be moving relative to the modeling table 104. Also, causing the head unit 102 to perform a scanning operation can be considered, for example, to cause the inkjet head of 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 scanning), a sub-scanning operation (X scanning), and a stacking direction scanning operation (Z scanning) as scanning operations.

In this case, the main scanning operation can be considered, for example, as 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, as an operation of moving relative to the object 50 being modeled in the sub-scanning direction, which is perpendicular to the main scanning direction. The sub-scanning operation can also be considered, for example, as an operation of moving in the sub-scanning direction relative to the modeling table 104 by a preset feed amount. In this example, the scan driver 106 causes the head unit 102 to perform main scanning and sub-scanning operations, thereby causing the head unit 102 to form an ink layer. The stacking direction scanning operation can be considered, for example, as 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.

The control unit 110 includes, for example, the CPU of the modeling device 12, and controls the various components of the modeling device 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 makes up 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.

Next, the configuration of the head unit 102 in the modeling device 12 will be described in more detail. Figure 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.

Of these inkjet heads 202, inkjet head 202s is an inkjet head that ejects the material of the support layer 52. For example, a known material for support layers can be suitably used as the material of the 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 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. 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 thought of as color expression achieved by combining process color inks in a subtractive color mixture method, for example. Process colors can be thought of as basic colors used in color expression, for example.

Inkjet head 202y, inkjet head 202m, inkjet head 202c, and inkjet head 202k (hereinafter referred to as inkjet heads 202y-k) are coloring inkjet heads 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 examples of colored material heads that eject colored materials. In this case, the colored materials can be considered, for example, to be colored materials used when forming a colored object. Furthermore, the colors YMCK are examples of process colors. The inks of the colors YMCK are examples of colored materials. The inks of each color, YMCK, can also be considered, for example, as coloring inks. The inkjet head 202t is an inkjet head that ejects clear ink. The clear ink can also 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.

The multiple ultraviolet light sources 204 are light sources (UV light sources) for curing ink and generate ultraviolet light that cures UV-curable ink. In this example, the multiple ultraviolet light sources 204 are arranged at one end and the other end of the head unit 102 in the main scanning direction, sandwiching the row of inkjet heads 202 between them. For example, UV LEDs (ultraviolet LEDs) can be suitably used as the ultraviolet light sources 204. Metal halide lamps, mercury lamps, and the like can also be considered as UV light sources 204. The flattening roller 206 is a flattening device for flattening the ink layer formed during the formation of the model 50. The flattening roller 206 can also be considered, for example, as a component for flattening a layer formed from a material ejected from an ejection head. In this example, the flattening roller 206 contacts the surface of the ink layer during the main scanning operation and flattens the ink layer by removing a portion of the ink before curing. By using a head unit 102 configured as described above, it is possible to appropriately form, for example, the ink layers that make up the modeled object 50. Furthermore, by forming multiple ink layers one on top of the other, it is possible to appropriately form, for example, the modeled object 50.

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 relative to the other inkjet heads.

Next, the configuration of the object 50 formed by the modeling device 12 of this example will be described in more detail. Figure 2 is a diagram illustrating the object 50 formed by the modeling device 12 of this example. Figure 2(a) is a diagram showing an example of the configuration of the object 50, and shows an example of the configuration of the X-Y cross section, which is a cross section of the object 50 perpendicular to the stacking direction (Z direction). In this case, the Y-Z cross section and X-Z cross section of the object 50 perpendicular to the X and Y directions also have similar configurations.

As explained above, in this example, the modeling device 12 (see FIG. 1) uses inkjet heads 202y-k (see FIG. 1) and the like to form a colored object 50. In this case, the modeling device 12 forms a model 50 with at least its surface colored. The coloring of the surface of the object 50 can be considered, for example, to mean that at least a portion of the area of the object 50 whose color is visible from the outside is colored. In this case, the modeling device 12 forms a model 50 that includes a light-reflecting region 152 and a colored region 154, as shown in the figure. If necessary, a support layer 52 (see FIG. 1) is formed around the object 50, etc.

The light-reflecting region 152 is a light-reflective region that reflects light incident from outside the model 50 via the colored region 154, etc. In this example, the modeling device 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 be a region that also serves as the 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 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 device 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 an area that is colored with coloring inks ejected from inkjet heads 202y-k. In this example, the modeling device 12 forms the colored region 154 around (outside) the light-reflecting region 152 using coloring inks ejected from inkjet heads 202y-k and clear ink ejected from inkjet head 202t (see Figure 1). In this case, the modeling device 12 expresses various colors by, for example, adjusting the amount of coloring ink ejected at each position. Clear ink is also used to compensate for variations in the amount of coloring ink that occur due to differences in color. This configuration allows, for example, each position in the colored region 154 to be appropriately colored with the desired color.

As explained above, in this example, the modeling device 12 forms the object 50 using an additive manufacturing method. In this case, the cross section of the object 50 taken along a plane parallel to the stacking direction can be considered to have a configuration in which multiple layers 172 overlap, as shown in FIG. 2(b), for example. FIG. 2(b) is a diagram illustrating an example of a configuration in which multiple layers 172 formed by additive manufacturing overlap. For ease of illustration, FIG. 2(b) shows an enlarged portion of the cross section of the object 50 taken along a plane parallel to the stacking direction, emphasizing the characteristics of each layer 172, for a portion of the object 50 having a different shape from the object 50 shown in FIG. 2(a). More specifically, in the configuration shown in FIG. 2(b), each of the multiple layers 172 is a layer of ink formed by the multiple inkjet heads 202 in the head unit 102 (see FIG. 1) during modeling of the object 50. Each layer 172 is stacked in the stacking direction, with the top side in the figure facing up vertically.

In this example, each layer 172 has a white portion 182 and a colored portion 184. The white portion 182 is a portion that will become part of the light-reflecting region 152 in the model 50. The colored portion 184 is a portion that will become part of the colored region 154 in the model 50. When modeling the model 50, the modeling device 12 forms the white portion 182 using white ink ejected from inkjet head 202w. Furthermore, the modeling device 12 forms the colored portion 184 around (outside) the white portion 182 using coloring ink ejected from inkjet heads 202y-k and clear ink ejected from inkjet head 202t. When forming each layer 172, the modeling device 12 flattens the layer 172 with a flattening roller 206, thereby forming the layer 172 to a predetermined thickness.

Furthermore, in order to produce a high-quality object 50, it is necessary to form each of the layers 172 that make up the object 50 with high precision. In this case, it is important that the modeling device 12 properly ejects ink from each inkjet head 202 and properly flattens the object using the flattening roller 206. In this case, if a problem occurs with the flattening operation, the quality of the object will be significantly reduced. Therefore, in this example, the modeling device 12 produces a confirmation object, which is an object used to check the operation of the modeling device 12, and adjustments are made to the modeling device 12 based on the condition of the confirmation object. With this configuration, it is possible to appropriately adjust the modeling device 12 so that, for example, an object with the configuration shown in FIG. 3 can be used as the confirmation object.

Figure 3 illustrates the confirmation object 300 used in this example. Figure 3(a) is a top view showing an example of the configuration of the confirmation object 300. The top view of the confirmation object 300 can be considered, for example, as a view of the confirmation object 300 from above in the stacking direction. The top view can also be considered, for example, as a view of the confirmation object 300 from the inkjet head 202 (see Figure 1) side in the positional relationship during printing in the printing device 12. Figure 3(b) is a side view of the confirmation object 300. The side view of the confirmation object 300 can be considered, for example, as a view of the confirmation object 300 from a side direction perpendicular to the up-down direction. Figure 3(b) also illustrates the confirmation object 300 as a side view of the confirmation object 300, viewed from a direction parallel to the sub-scanning direction. FIG. 3(c) is a bottom view of the confirmation object 300. The bottom view of the confirmation object 300 can be considered, for example, to be a view of the confirmation object 300 seen from the opposite side to the top view.

In this example, the confirmation object 300 includes a plate-shaped portion 302, a curved portion 304, and multiple step portions 306. The plate-shaped portion 302 is a plate-shaped portion having a main surface perpendicular to the stacking direction. In this case, the main surface can be considered, for example, as the surface with the largest area in the plate-shaped member. More specifically, in the plate-shaped portion 302 of this example, the upper and lower surfaces shown in Figures 3(a) and 3(c) can be considered as the main surfaces of the plate-shaped portion 302. Furthermore, in this example, the confirmation object 300 is an object having a portion of its surface colored. More specifically, in the confirmation object 300, a portion of each of the upper and lower surfaces is colored using at least one of the YMCK color inks, which are used for coloring. Furthermore, in the confirmation object 300, the portions other than the portions colored using one of the YMCK color inks are colored white using white ink. In this example, the confirmation object 300 has solid colored portions 312, character representation portions 314, line representation portions 316, and multiple color patterns 318 on both the top and bottom surfaces as areas that are at least partially colored. Furthermore, only the top surface has protruding characters 320. In addition to being partially colored, the confirmation object 300 also has a through-hole 322 as a feature.

Among these components of the confirmation object 300, the solid colored portion 312 is a portion that is colored by filling in at least a portion of a predetermined area using a coloring ink of one of the colors. Furthermore, on both the top and bottom surfaces of the confirmation object 300 in this example, the periphery of the solid colored portion 312 is formed in white using white ink, and is thus formed in a color different from the solid colored portion 312. In this case, it can be considered that a light-reflective area is formed using, for example, white ink between the solid colored portion 312 on the top surface and the solid colored portion 312 on the bottom surface. When forming such a solid colored portion 312, if the flattening roller 206 (see FIG. 1) of the modeling device 12 is misaligned or tilted, the flattening of the portion filled with coloring ink in the solid colored portion 312 may result in the coloring ink ejected to form the solid colored portion 312 being dragged by the flattening roller 206 beyond the intended range of the solid colored portion 312, resulting in unintended coloring outside the solid colored portion 312. Therefore, by forming such a solid colored portion 312, it is possible to check, for example, the flattening operation of the ink layer by the flattening roller 206. This also makes it possible to confirm, for example, if there is a problem with the flattening roller 206. Furthermore, it is possible to estimate the condition of the flattening roller 206 based on the disturbance in the condition of the solid colored portion 312 and make necessary adjustments, for example.

More specifically, the solid colored portion 312 in this example is formed using black ink as the coloring ink, with some portions left blank. In this case, the blank portions can be thought of as, for example, portions filled in with coloring ink and filled in white with white ink. In this example, the solid colored portion 312 includes blank characters of multiple different sizes as the blank portions. In this case, the blank characters can be thought of as, for example, characters rendered in white ink within the solid colored portion 312. Such solid colored portion 312 can also be thought of as, for example, a portion in which characters of multiple different sizes are rendered in white ink, with the remaining portions being filled in with black ink.

With this configuration, by filling the solid colored area 312 with black ink, it is possible to more easily and appropriately check for disturbances in the state of the solid colored area 312, for example, if the flattening operation of the flattening roller 206 drags the coloring ink outside the original range of the solid colored area 312. Furthermore, when forming a solid colored area 312 with this configuration, if the modeling device 12 is not adjusted correctly, it is possible that the outline characters in the solid colored area 312 will be distorted. In this case, for example, the flattening roller 206 may drag the black ink, causing portions of the outline characters to become distorted. Furthermore, by checking the maximum size of the outline characters that can be distinguished among the multiple sizes of outline characters included in the solid colored area 312, it is possible to check the state of the modeling device 12 and the flattening roller 206 in more detail. Furthermore, by forming such a solid colored portion 312, it is possible to check, for example, the filling operation by inkjet head 202k (see FIG. 1) based on the state of solid colored portion 312. It is also possible to check, for example, the state of inkjet head 202k and inkjet head 202w based on the state of solid colored portion 312 and its surroundings.

The character representation section 314 is an example of a character confirmation section for confirming characters represented using a colored material. In this example, the character representation section 314 forms a section in which characters of multiple different sizes are represented within an area where the characters are surrounded by white ink. Furthermore, characters of each size are represented using black ink. This configuration makes it possible, for example, to properly confirm how the characters are drawn during modeling. Furthermore, by representing characters of multiple sizes in the character representation section 314, it is possible to more properly confirm, for example, whether modeling is being performed with the desired quality. Furthermore, in this case, by checking which character sizes can be distinguished from the multiple character sizes included in the character representation section 314, it is possible to check the status of the modeling device 12, etc., in more detail, for example.

When creating a colored object, letters may be drawn on the surface of the object using coloring ink. In this case, if the drawn letters are distorted, it is likely to give the impression that the object is of low quality. For this reason, when adjusting the modeling device 12, it is preferable to confirm that the letters can be drawn appropriately with the required precision. In contrast, according to this example, by using a confirmation model 300 including a character representation unit 314, it is possible to appropriately confirm, for example, whether the letters can be drawn with the required precision, as described above. This also makes it possible to appropriately adjust the modeling device 12 so that it can create objects of the desired quality.

The line representation section 316 is an example of a line confirmation section for confirming lines represented using a colored material. In this example, the line representation section 316 forms a section representing multiple types of lines with different line widths. In this case, each line is formed in black ink within an area surrounded by white ink. Furthermore, multiple lines extending in multiple different directions are represented as lines of each width. This configuration makes it possible to appropriately confirm, for example, whether the modeling device 12 is adjusted to a state in which it can draw lines of various widths and directions that will serve as elements of an image or other element to be drawn on the surface of a model. Furthermore, in the illustrated configuration of the confirmation model 300, the line representation section 316 depicts lines of multiple widths: 0.05 mm, 0.1 mm, 0.2 mm, and 0.3 mm. By checking the state of lines with these line widths, for example, the modeling device 12 can be more appropriately adjusted to enable high-quality modeling.

The multiple color patterns 318 are portions that express a specific pattern using various colors. In this example, each of the multiple color patterns 318 expresses a pattern in which multiple rectangles of different sizes are nested. Furthermore, each rectangle is expressed by drawing the edges with lines of a specific thickness. In this case, the nesting of rectangles can be thought of, for example, as a smaller rectangle being placed inside a larger rectangle. In this case, the portions of the rectangles in the color pattern 318 other than the edges are white. Furthermore, in this example, the multiple rectangles in one color pattern 318 are drawn in the same color. However, the rectangles in different color patterns 318 are drawn in different colors. Furthermore, in this example, each color pattern 318 expresses a pattern drawn in different secondary colors. In this case, the secondary colors can be thought of, for example, as colors expressed using multiple coloring inks. More specifically, when YMCK inks are used as coloring inks, as in this example, red (R), green (G), and blue (B) can be expressed using two coloring inks selected from colors other than black. In this case, it is conceivable to draw, for example, patterns of each of the RGB colors as each of the multiple color patterns 318. In this configuration, by forming the multiple color patterns 318 using inks of colors other than black, which are used to form the solid colored portions 312 and the character representation portions 314, it is possible to properly check, for example, the results of modeling using coloring inks other than black. Furthermore, in this case, by forming each color pattern 318 using each of the RGB colors that are the base colors in the RGB color system, it is possible to more properly check, for example, how the modeled object is colored.

The protruding letters 320 are formed as three-dimensional letters that protrude from the surface of the plate-shaped portion 302. In this example, the protruding letters 320 are formed with a thickness equivalent to the thickness of multiple ink layers formed by additive manufacturing, with their upper surfaces colored. The protruding height of the protruding letters 320 may be, for example, approximately 200 μm (e.g., approximately 150 to 250 μm). The upper surfaces of the protruding letters 320 may be colored, for example, with any secondary color (e.g., red). By forming such protruding letters 320, it is possible, for example, to check the state of the modeling device 12 from a variety of perspectives. This also makes it possible, for example, to more appropriately adjust the modeling device 12 to a state that enables high-quality modeling.

The through-hole 322 is a hole that penetrates from the upper surface to the lower surface of the plate-shaped portion 302. It is conceivable to form the through-hole 322 with a diameter of, for example, approximately 1 mm (e.g., approximately 0.5 to 1.5 mm). Furthermore, when forming the confirmation object 300, for example, a support layer is formed inside the through-hole 322, and the modeling operation is performed using the modeling device 12, and the support layer is then removed to form the through-hole 322. By forming such a small-sized through-hole 322 and checking its condition, it is possible, for example, to check the condition of the modeling device 12 from a wider range of perspectives. This also makes it possible, for example, to more appropriately adjust the modeling device 12 to a state where high-quality modeling is possible. In this case, it is also possible to appropriately check, for example, whether the modeling device 12 is adjusted to a state where it can model an object with a through-hole.

By forming a confirmation object 300 including such a plate-like portion 302, the state of the modeling device 12 can be confirmed from various perspectives, as described above. Furthermore, in this case, by forming a solid colored portion 312, a character representation portion 314, a line representation portion 316, and a color pattern 318 on both the upper and lower surfaces, the state of the modeling device 12 can be more appropriately confirmed. Furthermore, as described above, in this example, the confirmation object 300 further includes a curved surface portion 304 and multiple step portions 306 in addition to the plate-like portion 302. In this case, the curved surface portion 304 and the multiple step portions 306 are formed so as to connect to the side surfaces of the confirmation object 300, for example. More specifically, in this example, the confirmation object 300 is formed with its longitudinal direction parallel to the main scanning direction during modeling by the modeling device 12. The curved surface portion 304 and the multiple step portions 306 are connected to the side surface of the plate-shaped portion 302 on one side in the main scanning direction. In this case, the curved surface portion 304 and the multiple step portions 306 are downstream of the plate-shaped portion 302 in the direction of movement of the flattening roller 206 during the main scanning operation that flattens the surface with the flattening roller 206. The positional relationship between the curved surface portion 304 and the multiple step portions 306 and the plate-shaped portion 302 can also be considered to be such that, for example, during the main scanning operation that flattens the surface with the flattening roller 206 during modeling, the portion corresponding to the plate-shaped portion 302 is flattened first, and the portions corresponding to the curved surface portion 304 and the multiple step portions 306 are flattened later.

Furthermore, in this example, the curved surface portion 304 and the multiple step portions 306 are portions formed with a more complex three-dimensional shape than the plate-shaped portion 302. More specifically, in this example, the curved surface portion 304 is a portion that includes a curved surface portion expressed by steps that occur depending on the modeling resolution of the modeling device 12. Each of the multiple step portions 306 is a staircase-shaped portion formed using multiple colors of coloring ink. By forming a confirmation object 300 that includes such a curved surface portion 304 and multiple step portions 306, it is possible to check, for example, the state of the modeling device 12 in more detail. Furthermore, it is conceivable that the curved surface portion 304 and each step portion 306 may be formed as a three-dimensional portion, for example, as shown in FIG. 4.

Figure 4 is a diagram that provides a more detailed explanation of the curved surface portion 304 and the step portion 306 in the confirmation object 300 (see Figure 3). Figure 4(a) is a cross-sectional view of the curved surface portion 304, showing a simplified example of the configuration of the curved surface portion 304 together with a portion of the plate-like portion 302. Figure 4(b) is a cross-sectional view of the step portion 306, showing a simplified example of the configuration of the step portion 306 together with a portion of the plate-like portion 302. Figure 4(c) is an enlarged schematic view showing the shape of the slope 342 in the step portion 306.

In this example, the curved surface portion 304 is a dome-shaped portion with a colored surface, and is formed with a colored surface by forming a colored region 154 around the light-reflecting region 152 inside. In this case, the dome-shaped shape can be considered, for example, to have an upper surface that gradually decreases in height from the highest point toward the periphery. The upper surface of the curved surface portion 304 can be considered, for example, to have a curved surface 332 of a predetermined shape. In this example, the colored region 154 on the curved surface portion 304 is colored black using black ink.

As explained above, in this example, the modeling device 12 (see Figure 1) uses additive manufacturing to create a model. In this case, various shapes of the model are approximated with a precision corresponding to the modeling resolution. As a result, in curved portions, such as the curved surface 332 on the upper surface of the curved portion 304, steps corresponding to the modeling resolution are formed. In this case, the steps corresponding to the modeling resolution can be considered to be steps whose height corresponds to the thickness of the ink layers layered in the additive manufacturing process. Therefore, so-called layering stripes typically occur in models created using additive manufacturing. The appearance of such layering stripes can be considered to reflect, for example, the state of the modeling device 12. More specifically, when each component of the modeling device 12 is properly adjusted to a predetermined correct state, the appearance of the layering stripes resulting from the steps can be considered to have a predetermined standard appearance. On the other hand, if any part of the modeling apparatus 12 is not properly adjusted and this affects the modeling operation, the appearance of the layering stripes may differ from the standard appearance. Therefore, by observing the layering stripes that appear on the curved surface 332 of the curved surface portion 304, it is possible to confirm, for example, the state of the modeling apparatus 12. Furthermore, the appearance of the curved surface 332 of the curved surface portion 304 may change depending on the flattening method performed by the flattening roller 206 (see FIG. 1 ) of the modeling apparatus 12. More specifically, for example, if the flattening roller 206 is not properly adjusted, the appearance of the layering stripes on the curved surface 332 may differ significantly from when the flattening roller 206 is properly adjusted. Therefore, by manufacturing a confirmation object 300 including a curved surface portion 304 configured as described above, it is possible to more appropriately confirm, for example, the flattening operation performed by the flattening roller 206. This also allows, for example, the flattening roller 206 to be more appropriately adjusted.

In this example, the curved surface portion 304 is an example of a flattening operation confirmation portion of the confirmation object 300. In this case, the flattening operation confirmation portion can be considered, for example, as a portion for confirming the flattening operation of the ink layer by the flattening roller 206 in the modeling device 12. As explained above, the flattening operation of the ink layer by the flattening roller 206 also affects portions other than the curved surface portion 304, such as the solid color portion 312 on the plate-like portion 302 of the confirmation object 300. Therefore, when checking the state of the confirmation object 300, it is possible to confirm the flattening operation of the ink layer by the flattening roller 206 based on the state of portions other than the curved surface portion 304. In this case, the curved surface portion 304 can also be considered, for example, as a configuration corresponding to a part of the flattening operation confirmation portion. The flattening operation confirmation portion can also be considered to include, for example, the curved surface portion 304 and the solid color portion 312.

In this example, the step portion 306 is a stepped portion with a colored surface. The colored region 154 is formed around the light-reflecting region 152 within the step portion 306, resulting in a colored surface. In this case, the stepped portion can be considered, for example, as a portion including multiple steps formed by overlapping multiple ink layers with different edge positions. These steps can be considered, for example, as steps whose height is an integer multiple of the thickness of the ink layer formed by the additive manufacturing method. The stepped portion of the step portion 306 can also be considered, for example, as a series of steps extending in a predetermined direction, forming a slope 342. In this case, the slope 342 can be considered, for example, as an oblique surface approximately represented by a series of steps that arise depending on the modeling resolution. The oblique surface can be considered, for example, as a surface that is non-parallel and non-orthogonal to the layering direction. For ease of illustration, in Figure 4(b), the slope 342, which is the stepped portion of the step portion 306, is simplified by a dashed line. When the surface portion of the slope 342 in Figure 4(b) is shown enlarged, the slope 342 can be considered to have a stepped shape, for example, as shown in Figure 4(c).

Furthermore, in the step portion 306, at least the upper surface of the slope 342, which is a staircase-like portion, can be considered to be colored using, for example, multiple colors of coloring inks ejected from multiple inkjet heads 202 out of the inkjet heads 202y-k (see Figure 1). In this case, the upper surface of the slope 342 can be considered, for example, as a surface visible from above the slope 342. The upper surface of the slope 342 can also be considered, for example, as a portion exposed on the upper surface of each ink layer stacked in the slope 342 portion of the step portion 306. As explained above, in this example, the confirmation object 300 has multiple step portions 306. In this case, for example, each step portion 306 can be colored with a different secondary color. More specifically, in this example, each step portion 306 is colored with red (R), green (G), and blue (B). In this case, the entire colored region 154 in each step portion 306 is colored in one of the RGB colors. This configuration allows for more appropriate confirmation of, for example, the coloring of portions with a three-dimensional shape. Furthermore, in the step portion 306, for example, the shape of each step on the slope 342 can be considered to be affected by the ink layer flattening operation performed by the flattening roller 206. Therefore, it is possible to confirm the ink layer flattening operation performed by the flattening roller 206 based on the state of the step portion 306. In this case, by using multiple colors of ink to form a three-dimensional step portion 306 colored in various colors, it is possible to confirm, for example, the flattening operation performed by the flattening roller 206 in more detail. In this case, for example, the step portion 306 can also be considered to be part of the flattening operation confirmation portion.

Next, the operation of the adjustment method for adjusting the modeling apparatus 12 (see FIG. 1) in this example will be described in more detail. FIG. 5 is a flowchart showing an example of the operation for adjusting the modeling apparatus 12. As explained above, in this example, the modeling apparatus 12 is adjusted using a confirmation object 300. In this case, for example, modeling object data representing the confirmation object 300 is supplied from the control PC 14 (see FIG. 1) to the modeling apparatus 12, causing the modeling apparatus 12 to model the confirmation object 300 (S102). In this case, the operation of step S102 is an example of the operation of the modeling stage. Also, in step S102, for example, a control value specifying the operation of the modeling apparatus 12 is set to a predetermined value. With this configuration, for example, the modeling conditions when modeling the confirmation object 300 can be appropriately adjusted to certain conditions. Furthermore, as can be understood from the configuration of the confirmation object 300 described above, in step S102 of this example, the modeling device 12 forms at least a portion of the confirmation object 300 using coloring inks ejected from at least one of the coloring inkjet heads 202y-k. This allows the modeling device 12 to model the confirmation object 300, at least a portion of which is colored. This configuration makes it possible, for example, to more easily and appropriately check the state of the confirmation object 300 in a later process. Furthermore, coloring at least a portion of the confirmation object 300 also makes it possible, for example, to check the state of the coloring inkjet heads 202y-k.

Following the operation in step S102, the state of the confirmation object 300 formed in step S102 is checked to confirm the formation results (S104), and it is determined whether it passes the predetermined criteria (S106). In this case, the operations in steps S104 and S106 are an example of the operations in the confirmation stage. In this example, in steps S104 and S106, the state of the confirmation object 300 formed by the forming device 12 to be adjusted is compared with a sample prepared in advance to confirm the state and determine whether it passes or fails. This sample is a comparative object created in advance by a reference forming device that has been appropriately adjusted. In this case, the reference forming device forms this sample, for example, based on object data representing the confirmation object 300. This sample can also be considered, for example, a limit sample that indicates the limits of the forming quality of the forming device.

In step S106, the criteria for determining whether the condition of the confirmation object 300 is acceptable or unacceptable may include, for example, a criterion for comparison with a sample and a criterion for judgment based on the state of the confirmation object 300 alone. In this case, the criteria for comparison with a sample may include, for example, criteria related to the reproducibility of thin lines, the appearance of layered stripes, and color unevenness. Regarding the reproducibility of thin lines, for example, a criterion may be used that compares lines of various line widths represented by the line representation section 316 (see FIG. 3) in the confirmation object 300 with the sample. In this case, for example, a criterion may be used that compares the line widths of the confirmation object 300 with those of the sample. Regarding the appearance of layered stripes, for example, a criterion may be used that compares the appearance of layered stripes on the curved surface 304 (see FIG. 3) of the confirmation object 300 and the state of the steps in the stepped section 306 (see FIG. 3) with those of the sample. In this case, for example, a criterion may be used that compares the appearance of layered stripes and steps with those of the sample.

Regarding color unevenness, for example, one possible standard is to compare the portions of the confirmation object 300 that are colored with coloring ink with a sample. In this case, for example, if the color unevenness is at the same level as the sample, the product may be deemed to have passed. Regarding color unevenness, it is preferable to check the color unevenness of both the flat and three-dimensional portions. In this case, for flat portions, for example, color unevenness occurring in the solid colored portion 312 (see Figure 3) of the confirmation object 300 may be checked. Regarding flat portions, for example, color unevenness occurring in the color pattern 318 (see Figure 3) of the confirmation object 300 may be checked. Regarding three-dimensional portions, for example, color unevenness occurring on the curved surface 332 of the curved portion 304 of the confirmation object 300 (see Figure 4) may be checked. Furthermore, with regard to three-dimensional shapes, it is also possible to check, for example, color unevenness occurring on the slope 342 of the step portion 306 in the confirmation object 300 (see FIG. 4 ). Regarding color unevenness, it is also preferable to check the color difference between passes. The color difference between passes can be considered, for example, as a difference in hue occurring between regions of the confirmation object 300 formed by different main scanning operations. In this case, it is also possible to consider that portions of the curved surface 332 of the curved portion 304 with different heights are formed by different main scanning operations. Therefore, color unevenness occurring on the curved surface 332 of the curved portion 304 can be considered, for example, as color unevenness corresponding to the color difference between passes. Regarding color differences between passes, it is also possible to check, for example, color unevenness occurring on the slope 342 of the step portion 306.

Considering the criteria for making a judgment based on the state of the confirmation object 300 alone, it is possible to check, for example, the readability of the characters drawn on the plate-like portion 302 of the confirmation object 300 and the state of the through-holes 322 (see Figure 3). In this case, for example, a criterion for passing the test may be that, among the various sizes of characters represented in the character representation portion 314 (see Figure 3) of the confirmation object 300, characters of a predetermined size (e.g., approximately 3 pt) are legible. Regarding the readability of the characters, a further judgment may be made on the readability of the outline characters drawn in the solid color portion 312. Regarding the state of the through-holes 322, it is possible to use a criterion for passing the test if the through-holes 322 are properly formed with a predetermined diameter (e.g., approximately 1 mm). Furthermore, in steps S104 and S106, it is also possible to check other items besides those mentioned above, and to make a pass/fail judgment based on the results of the check. In this case, for example, it is possible to check whether unintended streaks have occurred, and the shape and color appearance at each position on the confirmation object 300, and then make a pass/fail judgment based on these results.

Furthermore, as explained above, in this example, the solid colored portion 312 and the curved surface portion 304 of the confirmation object 300 can be considered to correspond to part of the flattening operation confirmation portion. In this case, it is possible to confirm, for example, whether flattening is being performed properly by the flattening roller 206, based on the state of these portions. Furthermore, if flattening is not being performed properly, it is possible to confirm, for example, the degree of deviation or tilt of the flattening roller 206, based on the state of these portions. With this configuration, it is possible to properly confirm, for example, the flattening operation by the flattening roller 206.

Furthermore, if all the criteria are met in step S106 (S106, Yes), it can be determined that the modeling device 12 has been appropriately adjusted. In this case, a model can be formed using the modeling device 12 without any further adjustments. On the other hand, if any of the criteria are not met in step S106 (S106, No), adjustments are made to the modeling device 12 based on the state of the confirmation model 300 confirmed in step S104 and the results of the determination in step S106 (S108). In this case, the operation in step S108 is an example of an operation in the adjustment stage.

Furthermore, in step S108, for example, based on the state of the confirmation object 300 confirmed in step S104, an estimate is made of which part of the modeling device 12 is causing a problem, and appropriate adjustments are made to that part so that the state of the confirmation object 300 approaches the state of the sample. More specifically, for example, if it is determined based on the state of the confirmation object 300 that there is a high possibility of a problem with the flattening operation by the flattening roller 206, adjustments may be made to the height or tilt of the flattening roller 206. In this case, for example, the appropriateness of the height of the flattening roller 206 may be determined based on the state of the layered stripes on the curved surface portion 304 of the confirmation object 300 and the state of the steps on the stepped portion 306. Furthermore, the direction and magnitude of the tilt of the flattening roller 206 may be determined based on, for example, the state of the curved surface portion 304 of the confirmation object 300 and the dragging of coloring ink near the solid colored portion 312. In this case, it is also possible to adjust the height and inclination of the flattening roller 206 based on the results of these judgments. With this configuration, it is possible to appropriately adjust the modeling device 12, for example, using a method that is suited to the configuration of the modeling device 12.

Furthermore, after the adjustment of the modeling device 12 is made in step S108, the process returns to step S102 and the subsequent operations are repeated. As a result, a new confirmation object 300 is formed by the adjusted modeling device 12, and the state of the modeling device 12 is confirmed again. According to this example, it is possible to appropriately confirm, for example, whether the confirmation object 300 is being formed with the desired quality. Furthermore, by adjusting the modeling device 12 based on the confirmation results of the state of the confirmation object 300, the adjustment of the modeling device 12 can be made appropriately. Furthermore, by repeatedly checking and adjusting the state of the modeling device 12 as necessary, it is possible to more appropriately adjust the modeling device 12, for example.

Next, we will provide supplementary explanations regarding the matters explained above. As explained above, in this example, adjustments are made to the modeling device 12 by having the modeling device 12 form the confirmation object 300. However, some of the adjustments that should be made to the modeling device 12 can be made without having to form the confirmation object 300. Therefore, for matters that can be adjusted without having to form the confirmation object 300, it is preferable to make the adjustments in advance before having the modeling device 12 form the confirmation object 300.

More specifically, when modeling using multiple inkjet heads 202, as in the modeling device 12 of this example, it is usually necessary to adjust the ink ejection characteristics of each inkjet head 202, the relative positional relationship of each inkjet head 202, and other factors in accordance with predetermined standards. Such adjustments can be appropriately performed without modeling the confirmation object 300, using the same or similar methods as those used to adjust the inkjet head ejection characteristics and positional relationship in an inkjet printer that prints two-dimensional images. In this case, for example, the modeling device 12 may adjust the ink ejection characteristics and positional relationship of the inkjet heads 202 by ejecting ink from each nozzle of each inkjet head 202 onto a sheet-like member (medium) such as film and checking the position and state of the ink dots formed on the medium. Such adjustment operations can be considered, for example, as pre-adjustment operations performed before the modeling device 12 models the confirmation object 300. Furthermore, the operation of the pre-adjustment stage can be, for example, an operation of adjusting the ejection characteristics and positional relationships of the multiple inkjets in advance. This configuration allows, for example, the adjustment of the modeling device 12 using the confirmation object 300 to be performed more accurately and appropriately. Furthermore, when adjusting the modeling device 12 using the confirmation object 300 after such pre-adjustment, it is possible to check and adjust items that are difficult to check without actually performing modeling with the modeling device 12, based on the state of the confirmation object 300. Furthermore, at least part of the checking and adjustment of such items can be, for example, checking and adjusting the flattening operation by the flattening roller 206, as described above.

Furthermore, when the above-described advance adjustments are made, it can be assumed that the ejection characteristics of the multiple inkjet heads 202 in the modeling device 12 are aligned according to the required accuracy when the modeling device 12 is made to model the confirmation object 300. In this case, for example, when checking the state of the confirmation object 300, by checking the coloring of a portion formed with the ink color ejected from one of the coloring inkjet heads 202y-k, it can be inferred that the same or similar state will be achieved even if the portion is formed with the ink color ejected from another inkjet head 202. More specifically, for example, in the confirmation object 300 of this example, the solid color portion 312, the character representation portion 314, the line representation portion 316, and the curved surface portion 304 are colored with only one color of ink (black ink). In this case, it can be assumed that the state of these regions will be the same or similar even if they are colored with, for example, another color of ink. Therefore, with this configuration, for example, the confirmation object 300 can be used to efficiently and appropriately check the status of the multiple inkjet heads 202. In this case, coloring these areas with black ink makes it possible to check the status more easily and appropriately. In addition, in the confirmation object 300 of this example, the color pattern 318 and the step portion 306 are colored with coloring inks of colors other than black. With this configuration, for example, the operation of the inkjet heads 202 for colors other than black can also be checked more appropriately.

As explained above, in the confirmation object 300 of this example, the solid colored portion 312 and the curved surface portion 304 can be considered part of the flattening operation confirmation portion. In this regard, for example, if the flattening roller 206 is not properly adjusted, it is conceivable that the quality of the modeling of portions of the confirmation object 300 other than the solid colored portion 312 and the curved surface portion 304 will also be affected. Therefore, the flattening operation confirmation portion can also be considered to include, for example, portions other than the solid colored portion 312 and the curved surface portion 304. More specifically, if the flattening roller 206 is not properly adjusted, it is conceivable that coloring ink will be dragged by the flattening roller 206 in areas other than the solid colored portion 312 and the curved surface portion 304. Furthermore, as a result, it is conceivable that the character representation portion 314 of the confirmation object 300 will have blurred or crushed characters, for example. In the line representation portion 316, for example, the state of the line may be distorted. In the color pattern 318, for example, the shape or color of the pattern may be distorted. In the protruding characters 320, for example, the shape of the protruding portion or the color of the characters may be distorted. In the through-holes 322, for example, the shape of the hole may be distorted or the hole may be filled in due to the surrounding ink being drawn to the position of the through-hole 322. Furthermore, in the stepped portion 306, for example, the shape or color of the step may be distorted. Therefore, it is preferable to check the flattening operation by the flattening roller 206 based on the state of each of these parts. In this case, at least a portion of these parts can be considered to be part of the flattening operation check portion.

The present invention can be suitably used, for example, as a method for adjusting a molding device.

10: Modeling system, 102: Head unit, 104: Modeling table, 106: Scanning driver, 110: Control unit, 12: Modeling device, 14: Control PC, 152: Light-reflecting area, 154: Colored area, 172: Layer, 182: White area, 184: Colored area, 202: Inkjet head, 204: Ultraviolet light source, 206: Flattening roller, 300: Confirmation object, 302: Plate-shaped portion, 304: Curved surface portion, 306: Step portion, 312: Solid colored portion, 314: Character representation portion, 316: Line representation portion, 318: Color pattern, 320: Protruding characters, 322: Through holes, 332: Curved surface, 342: Sloped surface, 50: Model, 52: Support layer

Claims (11)

1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling device based on the state of the confirmation object confirmed in the confirmation step,
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head,
In the modeling step, the modeling apparatus is caused to model the confirmation object having a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling apparatus ;
The method for adjusting a molding apparatus, wherein the flattening operation confirmation portion includes a curved surface portion expressed by steps that occur depending on the molding resolution of the molding apparatus . the modeling device includes a colored material head that is the ejection head that ejects a colored material that is a colored material used when modeling the colored object,
2. The method for adjusting a modeling apparatus according to claim 1 , wherein in the modeling step, at least a part of the confirmation model is formed using the colored material ejected from the colored material head. 1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling apparatus based on the state of the confirmation object confirmed in the confirmation step;
Equipped with
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head;
Equipped with
The ejection head includes:
a color material head that is the ejection head that ejects a color material that is a colored material used when forming the colored object;
a light-reflective material head , which is the ejection head that ejects the light-reflective material, which is the material that has light reflectivity;
Equipped with
a method for adjusting a modeling apparatus, characterized in that, in the modeling stage, at least a portion of the confirmation object is formed using the colored material ejected from the colored material head, the confirmation object has a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling apparatus, and further has a solid colored portion on its upper surface that is a portion of a predetermined range that is colored by filling it in with the colored material, and the periphery of the solid colored portion on the upper surface is formed in a color different from that of the solid colored portion using the light-reflective material. The method for adjusting a molding device described in claim 3, characterized in that the solid colored area is a part in which characters of multiple different sizes are represented in the color of the light-reflective material, and all but a few parts are colored by filling them in with the colored material. 5. The method for adjusting a molding apparatus according to claim 3 or 4, wherein, in the molding step, the molding apparatus is caused to mold the confirmation object, which also has the solid colored portion on its lower surface, and which has a light-reflective area formed using the light-reflective material between the solid colored portion on the upper surface and the solid colored portion on the lower surface. 1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling apparatus based on the state of the confirmation object confirmed in the confirmation step;
Equipped with
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head;
Equipped with
The ejection head includes:
a color material head that is the ejection head that ejects a color material that is a colored material used when forming the colored object;
a light-reflective material head , which is the ejection head that ejects the light-reflective material, which is the material that has light reflectivity;
Equipped with
in the modeling step, forming at least a part of the confirmation object using the colored material ejected from the colored material head, and allowing the modeling device to model the confirmation object, which has a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling device, and a character confirmation portion that is a portion for confirming the character expressed using the colored material;
A method for adjusting a molding device, characterized in that the character confirmation portion is a portion in which characters of multiple different sizes are represented using the colored material within an area where the surrounding area of the characters is the color of the light-reflective material. 1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling apparatus based on the state of the confirmation object confirmed in the confirmation step;
Equipped with
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head;
the ejection head includes a colored material head that ejects a colored material that is a colored material used when forming the colored object, and the ejection head includes a plurality of colored material heads that eject the colored materials of different colors,
in the modeling step, forming at least a part of the confirmation object using the colored material ejected from the colored material head, and causing the modeling device to model the confirmation object, which has a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling device, and a step -like portion formed by overlapping a plurality of the layers whose end positions are different from each other;
a step of coloring at least an upper surface of the stepped portion using a plurality of colored materials ejected from a plurality of the colored material heads ; 1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling apparatus based on the state of the confirmation object confirmed in the confirmation step;
Equipped with
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head;
the ejection head is a colored material head that ejects a colored material used when forming the colored object,
in the modeling step, forming at least a part of the confirmation object using the colored material ejected from the colored material head, and allowing the modeling device to model the confirmation object, which has a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling device, and a line confirmation portion that is a portion for confirming the line expressed using the colored material;
A method for adjusting a molding device, characterized in that the line confirmation portion is a portion that represents multiple types of lines with different line widths, and that each line width represents multiple lines extending in multiple different directions. 1. A method for adjusting a modeling device that forms a model by stacking layers formed of a modeling material, comprising:
a modeling step of forming a confirmation object, which is the object used to confirm an operation of the modeling device;
a confirmation step of confirming a state of the confirmation object formed in the modeling step;
an adjustment step of adjusting the modeling apparatus based on the state of the confirmation object confirmed in the confirmation step;
Equipped with
The molding device is
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head;
Equipped with
A method for adjusting a molding apparatus, characterized in that, in the molding stage, the molding apparatus is made to mold a confirmation object having a flattening operation confirmation portion for confirming the flattening operation of the layer by the flattening roller in the molding apparatus , and a through hole extending from the top surface to the bottom surface. A modeling system that forms a model by stacking layers formed of a modeling material,
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed of the material ejected from the ejection head,
forming, by the modeling device, a confirmation object which is the object used to confirm the operation of the modeling device;
the confirmation object has a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling apparatus,
the flattening operation confirmation portion includes a curved surface portion expressed by steps that occur depending on the modeling resolution of the modeling device,
A molding system characterized in that, during molding of the object, the molding device flattens the layer using the flattening roller, which has been adjusted based on the results of checking the state of the confirmation object. 1. A method for manufacturing a confirmation object, which is an object used to confirm operation of a modeling device that forms a model by stacking layers formed of modeling materials, comprising:
a discharge head that discharges the material for the modeling;
a flattening roller that flattens the layer formed by the material ejected from the ejection head,
forming the confirmation object having a flattening operation confirmation portion that is a portion for confirming the flattening operation of the layer by the flattening roller in the modeling apparatus;
a flattening operation confirmation portion including a curved surface portion expressed by steps that occur depending on the modeling resolution of the modeling device ;