Three-dimensional (3D) object printing system that compensates for misregistration

Abstract

The invention discloses a three-dimensional object printer. The three-dimensional object printer comprises a platen, a gantry positioned above the platen, an ejector head positioned on the gantry, a sensor, and a controller. The controller is configured to operate the ejector to eject at least one drop of material toward the platen at an upper build level and determine process and cross-process differentials between a fiducial and the at least one drop of material deposited on the upper build surface. The controller is also configured to determine an ejector head shift in a process direction and a cross-process direction associated with each of the plurality of build levels based at least in part on the determined process and cross-process differentials and a number of build levels between the base build level and the upper build level.

Description

technical field [0001] The devices and methods disclosed in this document relate to three-dimensional object printing, and more particularly, to diagnostic systems in three-dimensional object printers. Background technique [0002] Digital three-dimensional object manufacturing, also known as digital additive manufacturing, is a process of preparing three-dimensional solid objects of almost any shape from a digital model. Three-dimensional (3D) object manufacturing is an additive process in which one or more ejector heads of a 3D printer deposit material to gradually build up a part. Materials are deposited in discrete quantities, usually in a controlled manner, to form layers that collectively form the part. Initial layers of material are deposited onto the substrate, and subsequent layers are deposited on top of the previous layers. The substrate is supported on a platform that is movable relative to the jetting head so that each layer can be printed; either via the oper...

AI Technical Summary

Problems solved by technology

However, high-end 3D printers that include more expensive, precision-machined parts can also experience this same problem

Therefore, in both high-end and low-end printers, a painstaking and time-consuming setup procedure must be followed in order to ensure that all parts of the printer are aligned as closely as possible and thus produce the best possible parts

Unfortunately, these setup procedures are difficult to follow, time-consuming to implement, and add to the cost of the 3D printer

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