A method and system for printhead management in additive manufacturing

Abstract

This invention provides a printhead management method and system for additive manufacturing, relating to the field of additive manufacturing. The method collects printhead operating status data in real time using sensors and adjusts the nozzle speed of the printhead according to the printing material. It constructs the printhead printing path based on the geometric model of the printing task, material type, and printhead characteristics. The method monitors the nozzle speed and printing path in real time using sensors, collecting printing task load, nozzle status, and material flow data, and dynamically allocates the workload. When the task load, nozzle status, and material flow data exceed preset thresholds, a self-repair mechanism is activated, automatically cleaning the nozzles, adjusting the heating system temperature, and readjusting the material flow rate, automatically restoring the printhead to its normal operating state. This significantly improves printing accuracy, efficiency, quality, and stability in the additive manufacturing process.

Description

Technical Field

[0001] This invention relates to the field of additive manufacturing, and more specifically to a printhead management method and system for additive manufacturing. Background Technology

[0002] Additive manufacturing (AM), also known as 3D printing, is a manufacturing technology that creates three-dimensional objects by adding materials layer by layer. Unlike traditional subtractive manufacturing methods, additive manufacturing does not require cutting or milling operations and can directly generate actual objects from computer-generated 3D model files. It is widely used in aerospace, automotive, medical, construction, and many other industries. In additive manufacturing, a high-precision controlled print head deposits powder, liquid, or filament materials layer by layer to ultimately form the desired three-dimensional shape. In this process, the precision, stability, adaptability, and material control capabilities of the print head directly determine the quality of the finished product and the manufacturing efficiency.

[0003] As one of the core components of additive manufacturing equipment, the printhead's main function is to precisely jet or extrude raw materials onto the printing platform and perform high-precision path control according to the requirements of the printing task. The performance of the printhead has a crucial impact on the accuracy, surface smoothness, printing speed, and material utilization rate in the additive manufacturing process. Currently, common printhead types include FDM (Fused Deposition Modeling) printheads, SLA (Stereolithography) printheads, SLS (Selective Laser Sintering) printheads, and Jetting printheads. However, in existing technologies, printhead management methods are relatively simple, relying on manual adjustment or basic automatic control. This makes it difficult to adapt to multi-head printing or complex printing tasks. Most equipment can only achieve basic temperature control and material output control, lacking intelligent fault diagnosis and adaptive optimization.

[0004] Therefore, in order to solve the above problems, there is an urgent need for a more intelligent and automated printhead management method that can monitor and adjust the working status of the printhead in real time, optimize the printing process, especially in multi-head printing, complex material printing and fault detection, to achieve more efficient and accurate additive manufacturing. Summary of the Invention

[0005] In view of this, the purpose of this invention is to propose a printhead management method and system for additive manufacturing, which significantly improves the printing accuracy, efficiency, quality and stability in the additive manufacturing process by introducing intelligent monitoring, dynamic adjustment and path optimization, and solves the problem that the printhead management methods in the prior art are relatively simple.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] In view of the above objectives, in a first aspect, the present invention provides a printhead management method for additive manufacturing, comprising the following steps:

[0008] Start the printing system and perform a self-test, configure the printhead's operating parameters, initialize the printhead, and perform preheating and nozzle cleaning.

[0009] The system collects real-time data on the printhead's operating status using sensors and adjusts the nozzle speed of the printhead according to the printing material.

[0010] Based on the geometric model of the printing task, the material type, and the characteristics of the print head, construct the printing path of the print head;

[0011] The system uses sensors to monitor the nozzle speed and print path in real time, collects print workload, nozzle status and material flow data, and dynamically allocates workload.

[0012] When the workload, nozzle status, and material flow data exceed preset thresholds, a self-repair mechanism is activated to automatically clean the nozzles, adjust the heating system temperature, and readjust the material flow rate, thereby automatically restoring the printhead to normal working condition.

[0013] As a further aspect of the present invention, configuring the operating parameters of the printhead includes the following steps:

[0014] After the printing system is started, the embedded sensor performs a comprehensive self-test on the print head to check whether the nozzle, heating system, and feed mechanism are working properly.

[0015] The system identifies the characteristics of the printing material used in additive manufacturing, such as melting point, flowability, viscosity, and coefficient of thermal expansion, and dynamically adjusts the working parameters of the printhead, including nozzle temperature, material flow rate, and nozzle size.

[0016] As a further aspect of the present invention, the embedded sensor includes a temperature sensor, a pressure sensor, a photoelectric sensor, a nozzle speed sensor, a material flow sensor, and a displacement sensor. When the printhead is fully self-tested by the embedded sensor, the sensor detects the nozzle temperature, pressure, and nozzle working status in real time. After comparing with the standard threshold range, it detects whether there is blockage or abnormal temperature. If the nozzle temperature is too low, the system automatically adjusts the heater power. If the pressure is too high, the system adjusts the material feed speed or nozzle gap.

[0017] As a further aspect of the present invention, adjusting the nozzle speed of the print head according to the printing material includes the following steps:

[0018] Real-time acquisition of operating status data from sensors, including nozzle temperature, material flow rate, and printing speed;

[0019] The nozzle speed adjustment range is set according to the viscosity and melting point of the printing material;

[0020] A closed-loop control system is used to automatically adjust the nozzle speed in real time based on sensor data feedback.

[0021] As a further embodiment of the present invention, the closed-loop control system comprises a sensor module, a control module, and an execution module. The sensor module is responsible for real-time acquisition of operating status data, including nozzle temperature, material flow rate, nozzle pressure, and printing speed. The control module processes the sensor data and calculates the nozzle speed adjustment value. The execution module receives commands from the control module and adjusts the actual nozzle ejection speed and material feed speed. The closed-loop control system employs PID control and automatically adjusts the nozzle speed through closed-loop feedback and correction. After each nozzle speed adjustment, the sensor continues to monitor the nozzle's operating status data and provides real-time feedback to the control module. When the nozzle speed deviates from the expected adjustment range, the control system readjusts the nozzle speed.

[0022] As a further aspect of the present invention, constructing the printing path of the printhead includes the following steps:

[0023] Obtain the geometric model, material type, and printhead characteristics of the printing task; convert the geometric model of the printing task into a mesh, decompose the surface of the geometric model into a series of triangular or quadrilateral patches, where each mesh patch represents a local region of the model, and perform path calculation and connection planning between the mesh patches to plan the printing path;

[0024] The meshed geometric model is converted into a graph, where nodes represent points, edge points, and inflection points on the model surface, and edges represent the printing path from one location to another, with each edge assigned a weight.

[0025] The shortest path from the starting point to the target is calculated based on Dijkstra's algorithm, and path smoothing is performed on the basis of Dijkstra's algorithm.

[0026] The printing task is processed in layers, and the printing path of each layer is planned at different heights. For each layer, the printing path on a two-dimensional plane is planned using graphics, and the temperature of the path and the nozzle diameter are adjusted according to the melting point characteristics of the additive manufacturing material.

[0027] As a further aspect of the present invention, before dynamically allocating the workload, the printing area is further divided into multiple sub-areas, and different loads are allocated to each area according to printing accuracy and time. When dynamically allocating the workload, all data collected by the sensors are processed in real time. Based on the collected sensor data, a regression model is used to analyze and predict the printing load of each area, and the printing path is divided according to different loads. Based on the real-time monitoring data of nozzle speed and pressure, the nozzle speed is dynamically adjusted, and the workload is dynamically adjusted.

[0028] As a further aspect of the present invention, when identifying the characteristics of the printing material, such as melting point, flowability, viscosity, and coefficient of thermal expansion, the method includes establishing a database containing the characteristics of the printing material and loading information on the melting point, flowability, viscosity, and coefficient of thermal expansion of the printing material used in additive manufacturing.

[0029] As a further aspect of the present invention, when dynamically adjusting the working parameters of the printhead nozzle temperature, material flow rate, and nozzle size, the working status data of the material during the printing process is monitored in real time by sensors. The sensor data and material property database are used for analysis to identify the current state of the material. The nozzle temperature, material flow rate, and nozzle size of the printhead are adjusted according to the real-time monitoring data of the material. If an increase in material viscosity is detected, the nozzle temperature is increased to reduce the viscosity, and a closed-loop feedback control mechanism is implemented to optimize the printing parameters.

[0030] Secondly, the present invention provides a printhead management system for additive manufacturing, comprising:

[0031] The initialization module is used to start the printing system and perform a self-test, configure the printhead's operating parameters, initialize the printhead, and perform preheating and nozzle cleaning.

[0032] The data acquisition module is used to collect real-time data on the working status of the printhead through sensors and adjust the nozzle speed of the printhead according to the printing material.

[0033] The path planning module is used to construct the printing path of the print head based on the geometric model, material type, and print head characteristics of the printing task.

[0034] The load distribution module is used to monitor the nozzle speed and print path in real time through sensors, collect print workload, nozzle status and material flow data, and dynamically distribute the workload.

[0035] The repair and adjustment module is used to activate a self-repair mechanism when the task load, nozzle status, and material flow data exceed preset thresholds. This mechanism automatically cleans the nozzles, adjusts the heating system temperature, and readjusts the material flow rate, thus automatically restoring the printhead to its normal working state.

[0036] In another aspect, the present invention provides a computer device including a memory and a processor, the memory storing a computer program which, when executed by the processor, performs any of the above-described printhead management methods for additive manufacturing according to the present invention.

[0037] In another aspect, the present invention provides a computer-readable storage medium storing computer program instructions that, when executed, implement any of the above-described printhead management methods for additive manufacturing according to the present invention.

[0038] Compared with existing technologies, the printhead management method and system for additive manufacturing provided by this invention solves common problems in existing additive manufacturing processes, such as nozzle clogging, printing parameter mismatch, and unstable material flow, by real-time monitoring, data analysis, and dynamic adjustment of the printhead's working status, thereby improving print quality and production efficiency. Specific beneficial effects are as follows:

[0039] 1. Improved print quality and accuracy: This invention uses sensors to collect real-time data on the printhead's operating status (such as nozzle temperature, nozzle speed, and material flow rate), enabling accurate monitoring of changes in material flowability, viscosity, and thermal expansion during the printing process. When nozzle clogging or inappropriate printing parameters occur, the system can detect and adjust them immediately, ensuring the stability of the printing process and thus significantly improving print quality and accuracy.

[0040] 2. Automatic optimization of working parameters: Based on the characteristics of different materials (such as melting point, flowability, viscosity, etc.), this invention can dynamically adjust the working parameters of the print head (such as nozzle temperature, nozzle speed, material flow rate, etc.), thereby ensuring that the material flows under the most suitable conditions during each layer of printing. This dynamic adjustment method based on material characteristics and real-time data feedback can effectively avoid printing failures or substandard quality caused by improper parameter settings.

[0041] 3. Real-time monitoring and feedback repair mechanism: This invention integrates sensors to monitor nozzle status, workload, and material flow data in real time. By dynamically allocating the workload and detecting the printhead's operating status in real time, once an anomaly is detected (such as nozzle speed, nozzle status, or material flow exceeding preset thresholds), a self-repair mechanism is immediately activated. This mechanism can automatically clean the nozzles, adjust the heating system temperature, and readjust the material flow rate, effectively avoiding nozzle clogging and other common problems, thereby improving printhead stability and printing system reliability.

[0042] 4. Enhanced System Self-Repair Capability: This invention can automatically detect and repair potential printhead malfunctions, reducing manual intervention and improving the level of production automation. This self-repair mechanism not only extends the lifespan of the printhead but also minimizes production downtime and waste caused by equipment failure. Through intelligent management of the printhead, the system can adjust operating parameters in real time, avoiding unforeseen problems during production and improving production continuity and reliability.

[0043] 5. Improved Production Efficiency: This invention, through an automated printhead management method and system, not only allows for real-time adjustment of operating parameters during printing but also reduces errors caused by improper human operation. The repair and adjustment module can quickly respond to and fix potential problems, avoiding downtime caused by printhead blockage or other issues. These optimizations significantly improve production efficiency, especially in large-scale production and complex tasks.

[0044] 6. High scalability and adaptability: The printhead management method and system of this invention have strong adaptability and can support various types of additive manufacturing tasks. Through the analysis of the characteristics of different materials, task load monitoring, and intelligent algorithm optimization, the system can flexibly adjust according to different application scenarios. For example, for different printing materials (such as thermoplastics, metals, composite materials, etc.), the system can automatically optimize parameters such as nozzle temperature and material flow rate to adapt to the printing requirements of different materials.

[0045] 7. Reduced Human Intervention and Operational Errors: The automated monitoring and repair mechanism of this invention significantly reduces reliance on manual intervention, lowers the probability of operational errors, and reduces production losses caused by human error. This provides users with a more convenient and efficient printing experience, especially in applications requiring high precision and high-volume production, significantly improving production stability and consistency. Through automatic monitoring, real-time adjustment, and self-repair, the system reduces malfunctions caused by nozzle clogging, uneven temperature, and other issues, lowering the frequency and cost of equipment maintenance. Furthermore, the long lifespan and high stability of the printhead also reduce the expense of replacing parts due to equipment failure, thereby reducing overall maintenance costs.

[0046] In summary, the printhead management method and system provided by this invention significantly improve print quality, stability, and production efficiency in additive manufacturing processes, ensuring that parameters are always optimal during printing; enhancing the system's ability to respond to abnormal situations and preventing common malfunctions; reducing manual intervention and enhancing the system's self-repair and adaptive capabilities; and effectively improving production efficiency while reducing maintenance and production costs. This management method and system will have a significant technological driving effect on the additive manufacturing industry, especially for applications involving high precision, large-scale production, and complex materials, where it will have significant application value.

[0047] These or other aspects of this application will become more apparent from the following description of embodiments. It should be understood that the foregoing general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the application. Attached Figure Description

[0048] To more clearly illustrate the technical solutions in the embodiments of the present invention or related technologies, the accompanying drawings used in the description of the exemplary embodiments or related technologies will be briefly introduced below. The drawings are used to provide a further understanding of the present invention and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the present invention and do not constitute a limitation thereof. In the drawings:

[0049] Figure 1 This is a flowchart of a printhead management method for additive manufacturing according to an embodiment of the present invention.

[0050] Figure 2 This is a flowchart illustrating the configuration of printhead operating parameters in a printhead management method for additive manufacturing according to an embodiment of the present invention.

[0051] Figure 3 This is a flowchart illustrating the process of adjusting the nozzle speed of the printhead according to the printing material in a printhead management method for additive manufacturing according to an embodiment of the present invention.

[0052] Figure 4 This is a flowchart illustrating the process of constructing the printing path of the printhead in the printhead management method for additive manufacturing according to an embodiment of the present invention. Detailed Implementation

[0053] The present application will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0054] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be further described in detail below with reference to specific examples and the accompanying drawings. It should be understood that the specific embodiments described herein are merely illustrative and are not intended to limit the scope of this application.

[0055] It should be noted that all uses of "first" and "second" in the embodiments of the present invention are for the purpose of distinguishing two different entities or different parameters with the same name. Therefore, "first" and "second" are merely for convenience of expression and should not be construed as limiting the embodiments of the present invention. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, such as other steps or units inherent in a process, method, system, product, or device that includes a series of steps or units.

[0056] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0057] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0058] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0059] To address the issue of relatively simplistic printhead management methods in existing technologies, this invention proposes a printhead management method and system for additive manufacturing. By introducing intelligent monitoring, dynamic adjustment, and path optimization, it significantly improves printing accuracy, efficiency, quality, and stability in the additive manufacturing process.

[0060] See Figure 1 As shown, an embodiment of the present invention provides a printhead management method for additive manufacturing, the method comprising the following steps:

[0061] Step S10: Start the printing system and perform a self-test, configure the print head's operating parameters, initialize the print head, and perform preheating and nozzle cleaning.

[0062] In this step, see Figure 2 As shown, configuring the printhead's operating parameters includes the following steps:

[0063] Step S101: After the printing system is started, the embedded sensor performs a comprehensive self-test on the print head to check whether the nozzle, heating system and feed mechanism are working properly.

[0064] Step S102: Based on the printing material used in additive manufacturing, the system identifies the characteristics of the printing material, such as melting point, flowability, viscosity, and coefficient of thermal expansion, and dynamically adjusts the working parameters of the printhead nozzle temperature, material flow rate, and nozzle size.

[0065] In this embodiment, the sensor checks whether the nozzle temperature is within the normal range. If the temperature is too low, the heater power is automatically adjusted. Simultaneously, the sensor checks the nozzle pressure; if the pressure is too high, the system automatically adjusts the material feed rate to ensure stable nozzle operation. When the material viscosity increases, the system increases the nozzle temperature to decrease the material viscosity, thereby optimizing print quality.

[0066] The embedded sensors include temperature sensors, pressure sensors, photoelectric sensors, nozzle speed sensors, material flow sensors, and displacement sensors. When the printhead is fully self-tested using the embedded sensors, the sensors detect the temperature, pressure, and working status of the nozzles in real time. After comparing with the standard threshold range, they detect whether there is blockage or abnormal temperature. If the nozzle temperature is too low, the system automatically adjusts the heater power. If the pressure is too high, the system adjusts the material feed speed or nozzle gap.

[0067] When identifying the characteristics of printing materials, such as melting point, flowability, viscosity, and coefficient of thermal expansion, it is necessary to establish a database containing the characteristics of printing materials and load information on the melting point, flowability, viscosity, and coefficient of thermal expansion of the printing materials used in additive manufacturing.

[0068] When dynamically adjusting the printhead's nozzle temperature, material flow rate, and nozzle size, the system monitors the material's working status data in real time during printing using sensors. This data, along with a material property database, is analyzed to identify the material's current state. Based on the real-time monitoring data, the system adjusts the printhead's nozzle temperature, material flow rate, and nozzle size. If an increase in material viscosity is detected, the nozzle temperature is increased to reduce viscosity, and a closed-loop feedback control mechanism is implemented to optimize the printing parameters.

[0069] Step S20: Collect the working status data of the print head in real time through the sensor, and adjust the nozzle speed of the print head according to the printing material.

[0070] In this step, see Figure 3 As shown, adjusting the nozzle speed of the printhead according to the printing material includes the following steps:

[0071] Step S201: Acquire real-time working status data from the sensors, including nozzle temperature, material flow rate, and printing speed;

[0072] Step S202: Set the nozzle speed adjustment range according to the viscosity and melting point of the printing material;

[0073] Step S203: The nozzle speed is automatically adjusted in real time based on sensor data feedback using a closed-loop control system.

[0074] The closed-loop control system comprises a sensor module, a control module, and an execution module. The sensor module is responsible for real-time acquisition of operating status data, including nozzle temperature, material flow rate, nozzle pressure, and printing speed. The control module processes the sensor data and calculates the nozzle speed adjustment value. The execution module receives commands from the control module and adjusts the actual nozzle ejection speed and material feed speed. The closed-loop control system employs PID control and automatically adjusts the nozzle speed through closed-loop feedback and correction. After each nozzle speed adjustment, the sensor continues to monitor the nozzle's operating status data and provides real-time feedback to the control module. When the nozzle speed deviates from the expected adjustment range, the control system readjusts the nozzle speed.

[0075] For example, the sensor reads the nozzle temperature as 230°C, the material flow rate as 10 mm³ / s, and the printing speed as 50 mm / s. When setting the nozzle speed adjustment range according to the viscosity and melting point of the printing material, the nozzle speed is set between 30-60 mm / s when the printing material is PLA (low viscosity). When printing with higher viscosity materials (such as nylon), the nozzle speed is adjusted to a lower value (20 mm / s) to ensure smooth material flow.

[0076] A closed-loop control system is employed, dynamically adjusting the material feed rate and nozzle speed based on sensor data. If the nozzle temperature is too low or the material flow rate is insufficient, the system automatically reduces the nozzle speed and increases the nozzle temperature and material feed rate; conversely, if the nozzle temperature is too high or the material flow rate is excessive, the system increases the nozzle speed and decreases the nozzle temperature and material feed rate. During PLA printing, if the material flow rate decreases, the control module automatically increases the nozzle speed to ensure stable material output.

[0077] Step S30: Construct the printing path of the print head based on the geometric model, material type, and print head characteristics of the printing task.

[0078] In this step, see Figure 4 As shown, constructing the print path for the print head includes the following steps:

[0079] Step S301: Obtain the geometric model, material type, and printhead characteristics of the printing task; convert the geometric model of the printing task into a mesh, decompose the surface of the geometric model into a series of triangular or quadrilateral patches, where each mesh patch represents a local area of ​​the model, and perform path calculation and connection planning between the mesh patches to plan the printing path.

[0080] Step S302: Convert the meshed geometric model into a graph, where nodes represent points, edge points, and inflection points on the model surface, edges represent printing paths from one location to another, and assign weights to each edge.

[0081] Step S303: Calculate the shortest path from the starting point to the target based on Dijkstra's algorithm, and perform path smoothing processing based on Dijkstra's algorithm;

[0082] Step S304: Process the printing task into layers, plan the printing path at different heights on each layer, use graphics to plan the printing path on a two-dimensional plane for each layer, and adjust the path temperature and nozzle diameter according to the melting point characteristics of the additive manufacturing material.

[0083] For example, a 3D model of the printing task (e.g., a small mechanical part) is obtained, and the type of printing material (e.g., PLA) and printhead characteristics (e.g., nozzle diameter 0.4 mm) are input. The model surface is divided into multiple facets, each representing a local region. The printing path is calculated and connected between these facets. Based on the layer height information of the task, the printing task is divided into different layers. The nozzle temperature and nozzle diameter are adjusted according to the material characteristics of different layers. For example, the nozzle temperature is 230°C for the first layer and 240°C for the second layer to ensure good adhesion between layers.

[0084] Step S40: Monitor the nozzle speed and printing path in real time using sensors, collect printing workload, nozzle status and material flow data, and dynamically allocate workload.

[0085] Before dynamically allocating the workload, this step also includes dividing the printing area into multiple sub-areas, allocating different loads to each area based on printing accuracy and time, and dynamically allocating the workload. All data collected by the sensors are processed in real time. Based on the collected sensor data, a regression model is used to analyze and predict the printing load of each area, and the printing path is divided according to different loads. Based on the real-time monitoring data of nozzle speed and pressure, the nozzle speed is dynamically adjusted, and the workload is dynamically adjusted.

[0086] The system uses sensors to monitor nozzle speed, printing path, and material flow data in real time to ensure that the printhead works as planned. If the nozzle speed fluctuates, the sensor will report it in time, and the control module will make dynamic adjustments based on the data. When printing complex parts, higher workloads are allocated to areas with high precision requirements, while the workload is reduced in low precision areas to ensure efficiency.

[0087] Step S50: When the task load, nozzle status, and material flow data exceed the preset threshold, the self-repair mechanism is activated to automatically clean the nozzle, adjust the heating system temperature, and readjust the material flow rate, thereby automatically restoring the normal working state of the printhead.

[0088] In this step, if the sensor detects nozzle blockage, the system will automatically activate the cleaning program, start nozzle cleaning and adjust the heater power; if the material flow rate is unstable, the system will adjust the material supply mechanism to restore normal printing; if the temperature is too high, the system will reduce the heating power; if the temperature is too low, the system will heat the nozzle until it returns to normal operating temperature.

[0089] The printhead management method for additive manufacturing of this invention significantly improves printing quality and efficiency through real-time monitoring, dynamic adjustment of working parameters, and an automatic repair mechanism. In embodiments, the system combines sensor feedback data with a material property database to intelligently adjust parameters such as nozzle temperature, nozzle speed, and material flow rate. It also quickly restores normal operation in case of malfunctions, thereby improving the stability and automation level of the additive manufacturing process. This invention not only adjusts working parameters in real time during printing but also reduces errors caused by improper human operation. The repair and adjustment module can quickly respond to and repair potential problems, avoiding downtime caused by printhead blockage or other issues. These optimization measures significantly improve production efficiency, especially in large-scale production and complex tasks. The automated monitoring and repair mechanism of this invention greatly reduces reliance on manual intervention, lowers the probability of operational errors, and reduces production losses due to human error, providing users with a more convenient and efficient printing experience. It significantly improves production stability and consistency, especially in applications requiring high precision and high-volume production. Through automatic monitoring, real-time adjustment, and self-repair, the system reduces malfunctions caused by nozzle blockage, uneven temperature, and other problems, lowering the frequency and cost of equipment maintenance. In addition, the long lifespan and high stability of the printhead reduce the cost of replacing parts due to equipment failure, thereby reducing the overall maintenance cost.

[0090] Therefore, the printhead management method provided by this invention significantly improves print quality, stability, and production efficiency in the additive manufacturing process, ensuring that parameters are always optimal during printing; enhances the system's ability to respond to abnormal situations and avoids common failures; reduces manual intervention and enhances the system's self-repair and self-adaptive capabilities; and effectively improves production efficiency while reducing maintenance and production costs. The management method and system of this invention will have a significant technological driving effect on the additive manufacturing industry, especially for applications involving high precision, large-scale production, and complex materials, where they will have significant application value.

[0091] It should be noted that the above figures are merely illustrative of the processes included in the method according to exemplary embodiments of the present invention, and are not intended to be limiting. It is readily understood that the processes shown in the above figures do not indicate or limit the temporal order of these processes. Furthermore, it is readily understood that these processes may, for example, be executed synchronously or asynchronously in multiple modules.

[0092] It should be understood that although the above description follows a certain order, these steps are not necessarily executed in that order. Unless otherwise expressly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, some steps in this embodiment may include multiple steps or multiple stages, which are not necessarily completed at the same time, but may be executed at different times. The execution order of these steps or stages is not necessarily sequential, but may be performed alternately or in turn with other steps or at least a portion of steps or stages in other steps.

[0093] In a second aspect, the present invention also provides a printhead management system for additive manufacturing, comprising:

[0094] The initialization module is used to start the printing system and perform a self-test, configure the printhead's operating parameters, initialize the printhead, and perform preheating and nozzle cleaning.

[0095] The data acquisition module is used to collect real-time data on the working status of the printhead through sensors and adjust the nozzle speed of the printhead according to the printing material.

[0096] The path planning module is used to construct the printing path of the print head based on the geometric model, material type, and print head characteristics of the printing task.

[0097] The load distribution module is used to monitor the nozzle speed and print path in real time through sensors, collect print workload, nozzle status and material flow data, and dynamically distribute the workload.

[0098] The repair and adjustment module is used to activate a self-repair mechanism when the task load, nozzle status, and material flow data exceed preset thresholds. This mechanism automatically cleans the nozzles, adjusts the heating system temperature, and readjusts the material flow rate, thus automatically restoring the printhead to its normal working state.

[0099] Through the detailed steps described above, the printhead management system for additive manufacturing of the present invention is used to execute the steps of the printhead management method for additive manufacturing in the above embodiments, which will not be repeated here.

[0100] The printhead management system for additive manufacturing of this invention collects real-time printhead operating status data (such as nozzle temperature, nozzle speed, material flow rate, etc.) through sensors, enabling accurate monitoring of changes in material flowability, viscosity, and thermal expansion during the printing process. When nozzle clogging or inappropriate printing parameters occur, the system can detect and adjust them immediately, ensuring the stability of the printing process and significantly improving print quality and accuracy.

[0101] This invention dynamically adjusts printhead operating parameters (such as nozzle temperature, nozzle speed, and material flow rate) based on the characteristics of different materials (e.g., melting point, flow rate, viscosity), ensuring that the material flows under optimal conditions during each layer of printing. This dynamic adjustment method, based on material properties and real-time data feedback, effectively avoids printing failures or substandard quality caused by improper parameter settings. The invention integrates sensors to monitor nozzle status, workload, and material flow data in real time. By dynamically allocating the workload and detecting the printhead's operating status in real time, a self-repair mechanism is immediately activated upon detecting anomalies (e.g., nozzle speed, nozzle status, or material flow exceeding preset thresholds). This automatically cleans the nozzles, adjusts the heating system temperature, and readjusts the material flow rate, effectively preventing nozzle clogging and other common problems, thereby improving printhead stability and the reliability of the printing system.

[0102] The printhead management method and system of this invention have strong adaptability and can support various types of additive manufacturing tasks. Through the analysis of the characteristics of different materials, task load monitoring, and intelligent algorithm optimization, the system can flexibly adjust according to different application scenarios. For example, for different printing materials (such as thermoplastics, metals, composite materials, etc.), the system can automatically optimize parameters such as nozzle temperature and material flow rate to adapt to the printing requirements of different materials.

[0103] A third aspect of the present invention also provides a computer device, including a memory and a processor, wherein the memory stores a computer program that, when executed by the processor, implements the method of any of the above embodiments.

[0104] The computer device includes a processor and a memory, and may also include an input system and an output system. The processor, memory, input system, and output system can be connected via a bus or other means. The input system can receive input digital or character information and generate signal inputs related to the migration of the printhead for additive manufacturing. The output system may include a display device such as a screen.

[0105] Memory, as a non-volatile computer-readable storage medium, can be used to store non-volatile software programs, non-volatile computer-executable programs, and modules, such as the program instructions / modules corresponding to the printhead management method for additive manufacturing in the embodiments of this application. Memory may include a program storage area and a data storage area, wherein the program storage area may store an operating system and an application program required for at least one function; the data storage area may store data created by the use of the printhead management method for additive manufacturing, etc. Furthermore, memory may include high-speed random access memory and may also include non-volatile memory, such as at least one disk storage device, flash memory device, or other non-volatile solid-state storage device. In some embodiments, memory may optionally include memory remotely located relative to the processor, and these remote memories can be connected to the local module via a network. Examples of such networks include, but are not limited to, the Internet, corporate intranets, local area networks, mobile communication networks, and combinations thereof.

[0106] In some embodiments, the processor may be a central processing unit (CPU), a controller, a microcontroller, a microprocessor, or other data processing chip. The processor is typically used to control the overall operation of a computer device. In this embodiment, the processor is used to run program code stored in memory or process data. In this embodiment, the processors of multiple computer devices execute various server functions and data processing by running non-volatile software programs, instructions, and modules stored in memory, thereby implementing the steps of the printhead management method for additive manufacturing described in the above method embodiments.

[0107] It should be understood that, where there is no conflict, all the embodiments, features and advantages described above for the printhead management method for additive manufacturing according to the present invention are equally applicable to the printhead management and storage medium for additive manufacturing according to the present invention.

[0108] Those skilled in the art will also understand that the various exemplary logic blocks, modules, circuits, and algorithm steps described in conjunction with the disclosure herein can be implemented as electronic hardware, computer software, or a combination of both. To clearly illustrate this interchangeability between hardware and software, the functionality of various illustrative components, blocks, modules, circuits, and steps has been generally described. Whether this functionality is implemented as software or as hardware depends on the specific application and the design constraints imposed on the system as a whole. Those skilled in the art can implement the functionality in various ways for each specific application, but such implementation decisions should not be construed as departing from the scope of the embodiments disclosed herein.

[0109] Finally, it should be noted that the computer-readable storage medium (e.g., memory) described herein can be volatile memory or non-volatile memory, or may include both volatile and non-volatile memory. By way of example, and not limitation, non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory may include random access memory (RAM), which can act as external cache memory. By way of example, and not limitation, RAM can be obtained in various forms, such as synchronous RAM (DRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), and direct Rambus RAM (DRRAM). The storage devices disclosed herein are intended to include, but are not limited to, these and other suitable types of memory.

[0110] The various exemplary logic blocks, modules, and circuits described herein can be implemented or performed using the following components designed to perform the functions herein: general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs) or other programmable logic devices, discrete gate or transistor logic, discrete hardware components, or any combination of these components. A general-purpose processor may be a microprocessor, but alternatively, the processor may be any conventional processor, controller, microcontroller, or state machine. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors combined with a DSP, and / or any other such configuration.

[0111] The above are exemplary embodiments disclosed in this invention. However, it should be noted that various changes and modifications can be made without departing from the scope of the embodiments of this invention as defined by the claims. The functions, steps, and / or actions of the methods according to the disclosed embodiments described herein do not need to be performed in any particular order. Furthermore, although the elements disclosed in the embodiments of this invention may be described or claimed individually, they may be understood as multiple unless explicitly limited to a singular number.

[0112] It should be understood that, as used herein, the singular form "a" is intended to include the plural form as well, unless the context clearly supports an exception. It should also be understood that, as used herein, "and / or" refers to any and all possible combinations of one or more of the associatedly listed items. The embodiment numbers disclosed above are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0113] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary and is not intended to imply that the scope of the invention (including the claims) is limited to these examples. Within the framework of the invention, technical features of the above embodiments or different embodiments can be combined, and many other variations of different aspects of the invention exist, which are not provided in the details for the sake of brevity. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the protection scope of the invention.

Claims

1. A method for managing a printhead in additive manufacturing, characterized in that, The method includes the following steps: The printing system is started and performs a self-test, the printhead's operating parameters are configured, the printhead is initialized, and preheating and nozzle cleaning are performed. Configuring the printhead's operating parameters includes the following steps: After the printing system starts, a comprehensive self-test of the printhead is performed using embedded sensors to check whether the nozzles, heating system, and feed mechanism are functioning correctly. Based on the printing materials used in additive manufacturing, the system identifies the characteristics of the printing materials, such as melting point, flowability, viscosity, and coefficient of thermal expansion, and dynamically adjusts the printhead's nozzle temperature, material flow rate, and nozzle size operating parameters. The system collects real-time data on the printhead's operating status using sensors and adjusts the nozzle speed of the printhead according to the printing material. Based on the geometric model, material type, and printhead characteristics of the printing task, the printing path of the printhead is constructed. This construction includes the following steps: obtaining the geometric model, material type, and printhead characteristics of the printing task; converting the geometric model of the printing task into a mesh, decomposing the surface of the geometric model into a series of triangular or quadrilateral patches, where each mesh patch represents a local region of the model, and calculating and connecting the mesh patches to plan the printing path; converting the meshed geometric model into a graph, where nodes represent points, edge points, and inflection points on the model surface, edges represent printing paths from one location to another, and assigning weights to each edge; calculating the shortest path from the starting point to the target based on Dijkstra's algorithm, and performing path smoothing based on Dijkstra's algorithm; processing the printing task in layers, planning the printing path at different heights on each layer's printing path, and using a graphical plan for each layer on a two-dimensional plane, adjusting the path temperature and nozzle diameter according to the melting point characteristics of the additive manufacturing material; The system uses sensors to monitor the nozzle speed and print path in real time, collects print workload, nozzle status and material flow data, and dynamically allocates workload. When the workload, nozzle status, and material flow data exceed the preset threshold, the self-repair mechanism is activated to automatically clean the nozzles, adjust the heating system temperature, and readjust the material flow rate, thereby automatically restoring the printhead to normal working condition. Before dynamically allocating the workload, the printing area is divided into multiple sub-areas, and different loads are allocated to each area according to printing accuracy and time. When dynamically allocating the workload, all data collected by the sensors are processed in real time. Based on the collected sensor data, a regression model is used to analyze and predict the printing load of each area, and the printing path is divided according to different loads. Based on the real-time monitoring data of nozzle speed and pressure, the nozzle speed is dynamically adjusted, and the workload is dynamically adjusted.

2. The printhead management method for additive manufacturing as described in claim 1, characterized in that, The embedded sensors include temperature sensors, pressure sensors, photoelectric sensors, nozzle speed sensors, material flow sensors, and displacement sensors. When the printhead is fully self-tested using the embedded sensors, the sensors detect the temperature, pressure, and working status of the nozzle in real time. After comparing with the standard threshold range, they detect whether there is blockage or abnormal temperature. If the nozzle temperature is too low, the system automatically adjusts the heater power; if the pressure is too high, the system adjusts the material feed speed or nozzle gap.

3. The printhead management method for additive manufacturing as described in claim 1, characterized in that, Adjusting the nozzle speed of the printhead according to the printing material includes the following steps: Real-time acquisition of operating status data from sensors, including nozzle temperature, material flow rate, and printing speed; The nozzle speed adjustment range is set according to the viscosity and melting point of the printing material; A closed-loop control system is used to automatically adjust the nozzle speed in real time based on sensor data feedback.

4. The printhead management method for additive manufacturing as described in claim 3, characterized in that, The closed-loop control system consists of a sensor module, a control module, and an execution module. The sensor module is responsible for real-time acquisition of operating status data such as nozzle temperature, material flow rate, nozzle pressure, and printing speed. The control module is responsible for processing the sensor data and calculating the nozzle speed adjustment value. The execution module receives commands from the control module and adjusts the actual nozzle ejection speed and material feed speed. The closed-loop control system uses PID control and automatically adjusts the nozzle speed through closed-loop feedback and correction. After each nozzle speed adjustment, the sensor continues to monitor the nozzle's operating status data and provides real-time feedback to the control module. When the nozzle speed deviates from the expected adjustment range, the control system will adjust the nozzle speed again.

5. The printhead management method for additive manufacturing as described in claim 1, characterized in that, When identifying the properties of printing materials, such as melting point, flowability, viscosity, and coefficient of thermal expansion, it is necessary to establish a database containing the properties of printing materials and load information on the melting point, flowability, viscosity, and coefficient of thermal expansion of the printing materials used in additive manufacturing.

6. The printhead management method for additive manufacturing as described in claim 5, characterized in that, When dynamically adjusting the printhead's nozzle temperature, material flow rate, and nozzle size, the system monitors the material's working status data in real time during printing using sensors. This data, along with a material property database, is analyzed to identify the material's current state. Based on the real-time monitoring data, the system adjusts the printhead's nozzle temperature, material flow rate, and nozzle size. If an increase in material viscosity is detected, the nozzle temperature is increased to reduce viscosity, and a closed-loop feedback control mechanism is implemented to optimize the printing parameters.

7. A printhead management system for additive manufacturing, characterized in that, For performing the printhead management method for additive manufacturing as described in any one of claims 1-6, the system comprises: The initialization module is used to start the printing system and perform a self-test, configure the printhead's operating parameters, initialize the printhead, and perform preheating and nozzle cleaning. The data acquisition module is used to collect real-time data on the working status of the printhead through sensors and adjust the nozzle speed of the printhead according to the printing material. The path planning module is used to construct the printing path of the print head based on the geometric model, material type, and print head characteristics of the printing task. The load distribution module is used to monitor the nozzle speed and printing path in real time through sensors, collect printing task load, nozzle status and material flow data, and dynamically distribute the workload. The repair and adjustment module is used to activate a self-repair mechanism when the task load, nozzle status, and material flow data exceed preset thresholds. This mechanism automatically cleans the nozzles, adjusts the heating system temperature, and readjusts the material flow rate, thus automatically restoring the printhead to its normal working state.

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