3D printer with layer thickness adjustment control mechanism

Abstract

The application discloses a 3D printer with layer thickness adjusting control mechanism, and belongs to the technical field of 3D printing equipment, which comprises a rack, a feeder, a printing nozzle, a motion mechanism, a controller, a layer thickness detection assembly and a layer thickness adjusting execution assembly. The layer thickness detection assembly comprises a distance measuring sensor arranged at the rear side of the printing nozzle, and the distance measuring sensor is installed on the printing nozzle through a height calibration structure with a guide rail, a sliding seat and a locking piece to detect the formed printing layer after material deposition. The controller controls the layer thickness adjusting execution assembly to drive the printing platform to move slightly along the Z direction according to the deviation between the detected actual layer height or actual layer thickness and the theoretical height or preset layer thickness, and adjusts the discharging amount synchronously; the controller also sets a deviation threshold and a hierarchical compensation strategy to implement multi-layer gradual compensation for larger deviations. The application can form layer thickness closed-loop control, reduce layer thickness error accumulation, and improve the size precision, surface quality and forming stability of the printed part.

Description

Technical Field

[0001] This invention belongs to the field of 3D printing equipment technology, specifically relating to a 3D printer with a layer thickness adjustment and control mechanism, and more particularly to a 3D printer that can detect the actual layer thickness of the formed printed layer in real time and make closed-loop adjustments to the nozzle height, printing platform height or material output status based on the detection results. Background Technology

[0002] 3D printing is an additive manufacturing technology that forms three-dimensional solids by depositing materials layer by layer based on digital model files. Current 3D printers typically control the nozzle to move along the X and Y axes according to preset slicing parameters, and use a Z-axis lifting mechanism to stack layers according to a set thickness. Layer thickness, as a crucial parameter affecting printing accuracy, forming efficiency, and interlayer bonding quality, directly relates to the surface quality, dimensional accuracy, and structural strength of the printed part.

[0003] Current 3D printers typically use slicing software to set a fixed layer thickness before printing, and the nozzle or printing platform moves up and down layer by layer according to this fixed thickness during the printing process. However, in actual printing, factors such as the material's molten state, feed pressure, nozzle wear, platform flatness error, Z-axis drive clearance, thermal deformation, and changes in ambient temperature can all cause deviations between the actual deposited layer thickness and the preset layer thickness. When this deviation accumulates during multi-layer printing, it can easily lead to problems such as excessively thick or thin layers, uneven interlayer gaps, localized material buildup, and nozzle scraping of already formed layers, thus affecting the quality of the printed part.

[0004] While some 3D printers currently feature platform leveling or Z-axis compensation mechanisms, these structures are primarily used for initial calibration before printing, mainly addressing the issue of inconsistent initial spacing between the nozzle and the printing platform. They struggle to continuously monitor the actual height changes of the printed layers during the printing process and to dynamically correct layer thickness errors in a timely manner. Other machines rely on manual adjustment of the Z-axis offset or feed parameters after observing the printing status. This method depends on operator experience, resulting in low adjustment accuracy and response speed, failing to meet the requirements of continuous printing and high-precision molding.

[0005] Therefore, existing 3D printers lack a closed-loop layer thickness adjustment and control mechanism capable of detecting the actual layer thickness in real time during printing and automatically adjusting the nozzle, printing platform, or related actuators based on the detection results. This results in layer thickness control still primarily relying on preset parameters, making it difficult to promptly eliminate dynamic errors during the actual forming process. Therefore, it is necessary to propose a 3D printer with a layer thickness adjustment and control mechanism to improve layer thickness stability and forming accuracy during the printing process. Summary of the Invention

[0006] To address the aforementioned shortcomings of existing technologies, this invention aims to solve the problem that current 3D printers primarily rely on preset layer thickness parameters during the printing process, making it difficult to detect the actual layer thickness in real time and perform dynamic compensation. This leads to accumulated layer thickness errors and decreased molding accuracy. This invention provides a 3D printer with a layer thickness adjustment and control mechanism. By incorporating a layer thickness detection component, a controller, and a layer thickness adjustment execution component, the 3D printer can detect the actual height or thickness of the printed layers during the printing process and automatically adjust the relative distance between the nozzle and the printing platform based on the detection results, thereby forming a closed-loop layer thickness control.

[0007] The present invention adopts the following technical solution: a 3D printer with a layer thickness adjustment control mechanism, comprising: a frame, a feeder, a print head, a motion mechanism and a controller, wherein the printing platform is disposed on the frame, the print head moves relative to the printing platform through the motion mechanism, and the controller is electrically connected to the motion mechanism;

[0008] The 3D printer also includes a layer thickness detection component and a layer thickness adjustment execution component. The layer thickness detection component is located near the movement path of the print head and is used to detect the actual height or actual layer thickness of the printed layer. The layer thickness adjustment execution component is electrically connected to the controller and is used to adjust the relative distance between the print head and the printing platform. The controller controls the layer thickness adjustment execution component to perform compensation actions based on the deviation between the detection data obtained by the layer thickness detection component and the preset layer thickness data.

[0009] The layer thickness detection component includes a distance sensor positioned behind the printhead and along the printing path after the material deposition position of the printhead. This allows the distance sensor to detect the surface of the formed layer after material deposition. This configuration ensures the detection position corresponds to the actual material forming position, reducing the deviation between the static leveling results before printing and the actual layer thickness during printing.

[0010] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the layer thickness detection component is connected to the print head via a mounting bracket. The mounting bracket is provided with a height calibration structure, which is used to adjust the relative height between the distance sensor and the nozzle tip of the print head. Therefore, after changing the nozzle, adjusting the print head, or changing the printing material, the distance measurement reference can be calibrated, improving the correspondence between the detection data and the actual printing height of the nozzle.

[0011] According to another embodiment of the invention or any of the foregoing embodiments, the height calibration structure includes a guide rail, a sliding seat, and a locking member. The distance sensor or the sliding seat for mounting the distance sensor is movable along the guide rail and fixed to the mounting bracket by the locking member.

[0012] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the controller includes a layer thickness deviation calculation module and a compensation control module. The layer thickness deviation calculation module compares the height of the printed layer detected by the layer thickness detection component with the theoretical height corresponding to the current printed layer to obtain a layer thickness deviation value. The compensation control module controls the layer thickness adjustment execution component to perform compensation adjustment along the Z-axis based on the layer thickness deviation value. By comparing the actual detection result with the theoretical height, closed-loop correction during the printing process can be achieved.

[0013] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the compensation control module is provided with a deviation threshold. When the layer thickness deviation value is less than or equal to the deviation threshold, the controller maintains the current printing parameters; when the layer thickness deviation value is greater than the deviation threshold, the controller drives the layer thickness adjustment execution component to perform compensation. This setting can avoid frequent operation of the execution component due to small fluctuations in the sensor, thus improving the stability of the layer thickness adjustment process.

[0014] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the compensation control module is further provided with a graded compensation strategy, which includes single-layer instant compensation and multi-layer progressive compensation. When the layer thickness deviation value is within a first deviation range, the controller performs single-layer instant compensation in the current layer or the next printing path. When the layer thickness deviation value is within a second deviation range, the controller distributes the compensation amount to subsequent multi-layer printing processes to complete layer by layer. This avoids excessive adjustment at one time, which could cause the nozzle to scrape the printed layer or cause unstable interlayer bonding.

[0015] According to another embodiment of the invention or any of the foregoing embodiments, the 3D printer wherein the layer thickness adjustment execution component includes a lifting servo motor, a transmission component, and a printing platform. The lifting servo motor drives the printing platform to move slightly along the Z-axis via the transmission component. By applying the adjustment action to the lifting connecting seat, the controller controls the corresponding lifting support unit to compensate for layer thickness deviations in different printing areas. This enables the correction of local height errors, thermal deformation, or regional layer thickness errors during large-size printing.

[0016] According to another embodiment of the invention or any of the foregoing embodiments, the 3D printer further includes an output adjustment component electrically connected to the controller. When the controller controls the layer thickness adjustment execution component to change the relative distance between the print head and the print platform, the controller synchronously adjusts the output amount of the output adjustment component to match the compensated layer thickness. Through the linkage between layer thickness adjustment and output amount adjustment, material accumulation or insufficient material supply caused by changing only the Z-axis distance can be avoided.

[0017] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the controller is further configured to record layer thickness deviation data of consecutive multi-layers, and correct the Z-axis motion parameters and / or output parameters of subsequent printed layers based on the changing trend of layer thickness deviation of consecutive multi-layers. This not only corrects single-layer errors but also suppresses the accumulation of layer thickness errors during multi-layer printing, improving the overall dimensional accuracy of the printed parts.

[0018] According to another embodiment of the invention or any of the foregoing embodiments of the 3D printer, the controller is further connected to a display control panel, which is used to display layer thickness detection data, layer thickness deviation value, compensation status and material output adjustment status, and to input or modify preset layer thickness data, deviation threshold and graded compensation strategy parameters.

[0019] The beneficial effects of this invention are:

[0020] 1. This invention, by incorporating a controller, a layer thickness detection component, and a layer thickness adjustment execution component, enables the 3D printer to detect the actual height or thickness of the printed layers during the printing process and automatically adjust the relative distance between the nozzle and the printing platform based on the detection results, thereby forming a closed-loop layer thickness control. A distance sensor is positioned behind the printing nozzle, allowing it to detect the actual forming state after material deposition. Compared to static leveling before printing, this method better reflects the true layer thickness changes during the printing process. By recording layer thickness deviation data across multiple consecutive layers and correcting subsequent printing parameters based on the deviation trend, the accumulation of layer thickness errors is reduced, improving the dimensional accuracy and surface quality of the printed parts.

[0021] 2. This invention, by setting a height calibration structure, allows for adjustment of the relative height between the distance sensor and the nozzle. This facilitates the re-establishment of the detection benchmark after nozzle replacement, printhead maintenance, or changes in printing materials, thereby improving detection accuracy. By setting deviation thresholds and a tiered compensation strategy, it is possible to select immediate compensation or multi-layer progressive compensation based on the magnitude of layer thickness deviation, reducing the impact of frequent and excessive adjustments on printing stability.

[0022] 3. This invention links layer thickness adjustment with material output adjustment, so that Z-axis compensation matches material supply, avoiding problems such as local material accumulation, material shortage, or poor interlayer bonding during layer thickness adjustment. Attached Figure Description

[0023] Figure 1 This is a front view schematic diagram of the 3D printer with layer thickness adjustment control mechanism described in this invention;

[0024] Figure 2 This is a left-side schematic diagram of the 3D printer with a layer thickness adjustment control mechanism according to the present invention.

[0025] Figure 3 for Figure 2 An enlarged schematic diagram of part A;

[0026] Figure 4 This is a three-dimensional schematic diagram of the 3D printer with a layer thickness adjustment control mechanism according to the present invention.

[0027] Figure 5 This is a three-dimensional enlarged schematic diagram of the layer thickness detection component described in this invention;

[0028] In the picture,

[0029] 10. Rack;

[0030] 20. Feeder;

[0031] 30. Printer head;

[0032] 40. Sports equipment;

[0033] 50. Layer thickness detection component; 51. Distance sensor; 52. Mounting bracket; 53. Height calibration structure; 54. Locking element; 55. Sliding seat; 56. Guide rail;

[0034] 60. Layer thickness adjustment actuator; 61. Lifting servo motor; 62. Transmission components; 63. Printing platform. Detailed Implementation

[0035] The present invention will be further described below with reference to the accompanying drawings. It should be understood that the following embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention; conventional substitutions, combinations or adjustments made by those skilled in the art based on these embodiments without departing from the concept of the present invention should all be considered to fall within the technical concept of the present invention.

[0036] like Figures 1 to 5As shown, this embodiment provides a 3D printer with a layer thickness adjustment control mechanism, including a frame 10, a feeder 20, a print head 30, a motion mechanism 40, a layer thickness detection component 50, a layer thickness adjustment execution component 60, and a controller. The frame 10 forms the mounting base of the entire machine, supporting the feeder 20, print head 30, motion mechanism 40, layer thickness detection component 50, and layer thickness adjustment execution component 60. The feeder 20 is connected to the print head 30 and is used to feed printing material to the print head 30. The print head 30 is used to extrude and deposit molten or softened printing material to form stacked printing layers. The controller is electrically connected to the motion mechanism 40, layer thickness detection component 50, and layer thickness adjustment execution component 60, and is used to acquire detection data, calculate layer thickness deviation, and output compensation control commands.

[0037] like Figure 1 , Figure 2 and Figure 4 As shown, the motion mechanism 40 is mounted on the frame 10, and the print head 30 is positioned above the print platform 63 via the motion mechanism 40. The motion mechanism 40 drives the print head 30 to move relative to the print platform 63 along the X, Y, and Z directions, enabling the print head 30 to complete material deposition and layer-by-layer forming according to a pre-generated printing path. The print platform 63 is located below the print head 30 and supports the formed print and the printing layers being formed. An adjustable printing gap is formed between the print head 30 and the print platform 63, which directly affects the spread of a single layer of material, the deposition thickness, and the bonding quality between adjacent print layers.

[0038] like Figures 1 to 5 As shown, the layer thickness detection component 50 is positioned near the movement path of the print head 30 and after the material deposition position of the print head 30. The layer thickness detection component 50 includes a distance sensor 51, a mounting bracket 52, a height calibration structure 53, a locking element 54, a sliding seat 55, and a guide rail 56. The distance sensor 51 is mounted on the rear side of the print head 30 via the mounting bracket 52, so that the distance sensor 51 is located behind the material deposition position along the movement direction of the print head 30. After the print head 30 moves along the predetermined printing path and completes material extrusion, the distance sensor 51 can detect the distance to the surface of the newly formed or cooled and shaped printed layer and send the detected distance data to the controller.

[0039] The distance sensor 51 is positioned behind the print head 30, ensuring the detection position is adjacent to the actual material deposition position. Compared to statically leveling the print platform 63 only before printing, this structure directly reflects the actual forming height of the printing material after extrusion, spreading, cooling, and local shrinkage, allowing the controller to obtain layer thickness data closer to the actual printing state. By continuously monitoring the surface of the deposited layer during printing, layer thickness errors caused by factors such as abnormal material output, nozzle wear, local platform deformation, Z-axis transmission deviation, and thermal deformation can be detected in a timely manner, reducing the possibility of errors accumulating layer by layer in subsequent print layers.

[0040] like Figure 3 and Figure 5 As shown, the mounting bracket 52 is connected to the outside of the print head 30, and the distance sensor 51 is mounted on the mounting bracket 52 via a sliding seat 55. A guide rail 56 is disposed on the mounting bracket 52, and the sliding seat 55 slides along the guide rail 56, allowing the distance sensor 51 to move along the guide rail 56 with the sliding seat 55. A locking member 54 is mounted on the sliding seat 55 or the mounting bracket 52. After the distance sensor 51 is adjusted to the predetermined detection position, the locking member 54 is used to fix the sliding seat 55 to the corresponding position on the guide rail 56.

[0041] The height calibration structure 53, composed of a guide rail 56, a sliding seat 55, and a locking element 54, adjusts the relative height between the distance sensor 51 and the nozzle tip of the print head 30. After changing nozzles of different lengths, disassembling or assembling the print head 30, adjusting the position of the mounting bracket 52, or changing the printing material, the locking element 54 can be loosened, allowing the sliding seat 55 to move the distance sensor 51 along the guide rail 56. The detection height of the distance sensor 51 is then recalibrated based on the nozzle tip reference position and fixed by the locking element 54. This structure ensures a stable correspondence between the detection reference of the distance sensor 51 and the actual nozzle output position, preventing data distortion due to nozzle specification changes or assembly errors, and improving the accuracy of the correspondence between the layer thickness detection result and the actual printing height.

[0042] like Figure 1 and Figure 2 As shown, the layer thickness adjustment actuator 60 is installed between the frame 10 and the printing platform 63. The layer thickness adjustment actuator 60 includes a lifting servo motor 61, a transmission component 62, and the printing platform 63. The lifting servo motor 61 is mounted on the frame 10, and the transmission component 62 connects the lifting servo motor 61 and the printing platform 63. The lifting servo motor 61 drives the printing platform 63 to move slightly up and down along the Z direction through the transmission component 62. The transmission component 62 can be a lead screw and nut pair, a synchronous belt drive assembly, a gear and rack drive assembly, a worm gear drive assembly, or other transmission structures capable of achieving fine lifting control.

[0043] The layer thickness adjustment actuator 60 drives the printing platform 63 to move along the Z-axis, changing the relative distance between the print head 30 and the printing platform 63. When the actual printed layer thickness is detected to be greater than the preset layer thickness, the controller can control the lifting servo motor 61 to move the printing platform 63 slightly away from the print head 30 to appropriately increase the nozzle spacing in the subsequent printing path. When the actual printed layer thickness is detected to be less than the preset layer thickness, the controller can control the lifting servo motor 61 to move the printing platform 63 slightly closer to the print head 30 to decrease the nozzle spacing in the subsequent printing path. By performing slight height compensation on the printing platform 63, the Z-axis layer thickness error can be corrected without significantly changing the planar motion trajectory of the print head 30, maintaining a relatively stable interval relationship between the formed printed layer and the subsequent printed layer.

[0044] In another embodiment, the layer thickness adjustment execution component 60 can be equipped with multiple lifting support units corresponding to different printing areas. Each lifting support unit includes a lifting servo motor 61 and a transmission component 62, which together support the printing platform 63. When the printed part is large or the printing platform 63 experiences regional height deviations due to thermal deformation or load changes, the controller can perform differentiated adjustments to the lifting support units in the corresponding areas based on the detection data obtained by the layer thickness detection component 50 in different areas. This structure can provide targeted compensation for local warping, local sinking, or regional thermal expansion of the printing platform 63, improving the layer thickness consistency of large-size printed parts in different areas.

[0045] The controller includes a layer thickness deviation calculation module and a compensation control module. The layer thickness deviation calculation module receives detection data from the distance sensor 51 and, based on the calibration relationship between the distance sensor 51 and the nozzle tip of the print head 30, calculates the actual height or actual layer thickness of the printed layer surface. The module compares the actual height or actual layer thickness with the theoretical height or preset layer thickness corresponding to the current printed layer to obtain the layer thickness deviation value. The compensation control module generates a compensation command based on the layer thickness deviation value and controls the layer thickness adjustment execution component 60 to perform Z-axis compensation adjustment.

[0046] For example, when the theoretical height of the current printed layer is H0 and the actual printed layer height detected by the layer thickness detection component 50 is H1, the controller can determine the layer thickness deviation value based on the difference between H1 and H0. When the actual printed layer height is higher than the theoretical height, it indicates that there may be material accumulation, excessive output, insufficient nozzle gap, or local platform lifting in the current printing area; when the actual printed layer height is lower than the theoretical height, it indicates that there may be insufficient output, insufficient material spreading, excessive nozzle gap, or local platform sinking in the current printing area. Based on this, the controller controls the layer thickness adjustment execution component 60 to compensate, so that the actual forming height of subsequent printed layers gradually returns to the preset range.

[0047] The compensation control module is set with a deviation threshold. When the layer thickness deviation is less than or equal to the deviation threshold, the controller maintains the current printing parameters and does not drive the layer thickness adjustment actuator 60 to perform compensation. When the layer thickness deviation is greater than the deviation threshold, the controller controls the layer thickness adjustment actuator 60 to perform the compensation action. The deviation threshold can be set according to the type of printing material, nozzle diameter, preset layer thickness, printing speed, and target accuracy. By setting the deviation threshold, normal detection fluctuations of the ranging sensor 51, microscopic undulations on the material surface, and instantaneous environmental disturbances can be excluded from the compensation range, avoiding frequent start-stop of the layer thickness adjustment actuator 60 due to minor errors, improving the stability of the entire machine operation, and reducing ineffective movements of the transmission mechanism.

[0048] The compensation control module also features a tiered compensation strategy, including single-layer instant compensation and multi-layer progressive compensation. When the layer thickness deviation is within the first deviation range, the controller employs single-layer instant compensation, controlling the layer thickness adjustment execution component 60 to complete the corresponding compensation amount in the subsequent printing path of the current layer or before the start of the next printing layer. When the layer thickness deviation is within the second deviation range, the controller employs multi-layer progressive compensation, distributing the required compensation amount to multiple subsequent printing layers for layer-by-layer implementation.

[0049] The first deviation range corresponds to a small layer thickness deviation. In this case, single-layer instant compensation can quickly restore the target printing spacing and reduce the transmission of errors to subsequent printing layers. The second deviation range corresponds to a larger layer thickness deviation. In this case, if a large Z-axis adjustment is made at once, the print head 30 may suddenly move closer to the already formed printing layer, causing nozzle scraping, material accumulation, or excessive interlayer compaction; it may also cause the print head 30 to suddenly move away from the printing layer, causing material stringing, suspended deposition, or insufficient interlayer bonding. Multi-layer progressive compensation, by distributing a larger compensation amount across multiple printing layers, makes the change in printing spacing smoother, which is beneficial for maintaining the stability of the material deposition state and interlayer bonding state.

[0050] like Figure 1 and Figure 4 As shown, the 3D printer in this embodiment also includes a material output adjustment component, which is electrically connected to the controller and works in conjunction with the feeder 20 and the print head 30. The material output adjustment component is used to adjust the speed, pressure, or output amount of printing material delivered by the feeder 20 to the print head 30. When the controller controls the layer thickness adjustment execution component 60 to change the relative distance between the print head 30 and the printing platform 63, the controller synchronously controls the material output adjustment component to adjust the output amount of printing material.

[0051] For example, when the controller reduces the relative distance between the print head 30 and the printing platform 63, the controller can appropriately reduce the output to avoid excessive material accumulation in the small nozzle gap; when the controller increases the relative distance between the print head 30 and the printing platform 63, the controller can appropriately increase the output to avoid insufficient material causing the printed layer to be too thin, localized material breaks, or insufficient interlayer bonding. By linking Z-axis layer thickness compensation with output adjustment, the material deposition amount can be matched with the compensated printing gap, avoiding problems such as localized material accumulation, insufficient material, increased porosity, or decreased interlayer bonding quality caused by simply adjusting the height of the printing platform 63.

[0052] The controller is also used to record layer thickness deviation data for consecutive multi-layer printing and analyze the trend of layer thickness deviation changes for consecutive multi-layer printing. When the layer thickness deviation values ​​of consecutive multi-layer printing show an increasing trend in the same direction, the controller can determine that there is a continuous systematic error in the printing process and correct the Z-axis motion parameters and / or output parameters of subsequent printing layers in advance based on the deviation trend. For example, when the actual height of several consecutive printing layers is consistently higher than the theoretical height, the controller can gradually increase the relative distance between the print head 30 and the printing platform 63 in the subsequent printing path, or appropriately reduce the output of the feeder 20; when the actual height of several consecutive printing layers is consistently lower than the theoretical height, the controller can gradually decrease the relative distance between the print head 30 and the printing platform 63, or appropriately increase the output of the feeder 20.

[0053] Continuous layer thickness deviation trend analysis enables the controller not only to correct occasional errors in a single layer, but also to identify persistent deviations caused by nozzle wear, changes in feed resistance, changes in material viscosity, platform thermal deformation, or Z-axis transmission errors. By performing predictive corrections based on multi-layer data, the cumulative effect of layer thickness errors can be reduced, improving the overall dimensional accuracy of printed parts, surface flatness, and internal structural density.

[0054] The controller is also connected to a display control panel, which displays the actual height data detected by the layer thickness detection component 50, the layer thickness deviation value, the compensation status of the layer thickness adjustment execution component 60, and the operating status of the material output adjustment component. The operator can input or modify preset layer thickness data, deviation thresholds, first deviation range, second deviation range, single-layer instant compensation amount, number of progressive compensation layers, and material output adjustment parameters through the display control panel. By setting the display control panel, the operator can intuitively understand the layer thickness changes during the printing process and adjust the control parameters for different materials, nozzle specifications, and printing accuracy requirements, improving the applicability and ease of operation of the equipment.

[0055] The working process of this embodiment is as follows: Before printing begins, the operator adjusts the position of the sliding seat 55 on the guide rail 56 according to the nozzle specifications and printing material, so that a corresponding height reference is established between the distance sensor 51 and the nozzle end of the print head 30. Then, the sliding seat 55 is fixed by the locking member 54. During printing, the motion mechanism 40 drives the print head 30 to move along a predetermined path, and the feeder 20 delivers printing material to the print head 30. The print head 30 deposits the printing material layer by layer onto the printing platform 63 or the surface of the already formed printing layer.

[0056] After the print head 30 completes a printing path, the distance sensor 51 located behind the print head 30 detects the surface of the printed layer in the corresponding area and transmits the detection data to the controller. The controller calculates the actual layer thickness or actual layer height based on the detection data and compares it with the theoretical height or preset layer thickness of the current printed layer. When the layer thickness deviation does not exceed the deviation threshold, the controller maintains the current printing parameters; when the layer thickness deviation exceeds the deviation threshold, the controller selects a single-layer instant compensation or multi-layer progressive compensation strategy based on the magnitude of the deviation, controls the lifting servo motor 61 to drive the printing platform 63 to move slightly in the Z direction via the transmission component 62, and simultaneously controls the material output adjustment component to adjust the material output of the feeder 20 accordingly.

[0057] Through the aforementioned closed-loop adjustment process, the distance sensor 51 behind the print head 30 can detect the actual state of the printed layer after material deposition. Based on the detection results, the controller collaboratively corrects the relative distance between the print head 30 and the printing platform 63, as well as the amount of printed material output. This structure can reduce the deviation between the preset layer thickness and the actual layer thickness, suppress the accumulation of layer thickness errors during continuous printing, and reduce the probability of problems such as nozzle scratching, local material accumulation, insufficient material, uneven interlayer gaps, and poor interlayer bonding, thereby improving the surface quality, dimensional accuracy, and forming stability of 3D printed parts.

[0058] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the above embodiments are merely illustrative of the technical concept and characteristics of the present invention, intended to enable those skilled in the art to understand and implement the invention, and should not be construed as limiting the scope of protection of the present invention. All equivalent changes or modifications made in accordance with the spirit and essence of the present invention should be covered within the scope of protection of the present invention.

Claims

1. A 3D printer with a layer thickness adjustment control mechanism, comprising: The machine includes a frame (10), a feeder, a print head (30), a motion mechanism (40), and a controller. The printing platform (63) is mounted on the frame (10). The print head (30) moves relative to the printing platform (63) via the motion mechanism (40). The controller is electrically connected to the motion mechanism (40). The 3D printer is characterized by the following features: it further includes a layer thickness detection component (50) and a layer thickness adjustment execution component (60). The layer thickness detection component (50) is located near the movement path of the printing nozzle (30) and is used to detect the actual height or actual layer thickness of the printed layer. The layer thickness adjustment execution component (60) is electrically connected to the controller and is used to adjust the relative distance between the printing nozzle (30) and the printing platform (63). The controller controls the layer thickness adjustment execution component (60) to perform a compensation action based on the deviation between the detection data obtained by the layer thickness detection component (50) and the preset layer thickness data. The layer thickness detection component (50) includes a distance sensor (51), which is located on the rear side of the print head (30) and along the printing path after the material deposition position of the print head (30), so that the distance sensor (51) can detect the surface of the formed layer after the material is deposited.

2. A 3D printer with a layer thickness adjustment control mechanism according to claim 1, characterized in that: The layer thickness detection component (50) is connected to the print head (30) via a mounting bracket (52). The mounting bracket (52) is provided with a height calibration structure (53), which is used to adjust the relative height between the distance sensor (51) and the nozzle end of the print head (30).

3. A 3D printer with a layer thickness adjustment control mechanism according to claim 2, characterized in that: The height calibration structure (53) includes a guide rail (56), a sliding seat (55), and a locking member (54). The distance sensor (51) or the sliding seat (55) for mounting the distance sensor (51) can move along the guide rail (56) and be fixed to the mounting bracket (52) by the locking member (54).

4. A 3D printer with a layer thickness adjustment control mechanism according to claim 1, characterized in that: The controller is equipped with a layer thickness deviation calculation module and a compensation control module. The layer thickness deviation calculation module is used to compare the height of the printed layer detected by the layer thickness detection component (50) with the theoretical height corresponding to the current printed layer, and obtain the layer thickness deviation value. The compensation control module controls the layer thickness adjustment execution component (60) to perform compensation adjustment along the Z direction according to the layer thickness deviation value.

5. A 3D printer with a layer thickness adjustment control mechanism according to claim 4, characterized in that: The compensation control module is set with a deviation threshold. When the layer thickness deviation value is less than or equal to the deviation threshold, the controller maintains the current printing parameters. When the layer thickness deviation value is greater than the deviation threshold, the controller drives the layer thickness adjustment execution component (60) to perform compensation.

6. A 3D printer with a layer thickness adjustment control mechanism according to claim 5, characterized in that: The compensation control module is also equipped with a hierarchical compensation strategy, which includes single-layer instant compensation and multi-layer progressive compensation. When the layer thickness deviation value is within the first deviation range, the controller performs single-layer instant compensation in the current layer or the next printing path. When the layer thickness deviation value is within the second deviation range, the controller allocates the compensation amount to subsequent multi-layer printing processes to be completed layer by layer.

7. A 3D printer with a layer thickness adjustment control mechanism according to claim 1, characterized in that: The layer thickness adjustment execution component (60) includes a lifting servo motor (61), a transmission component (62), and a printing platform (63). The lifting servo motor (61) drives the printing platform (63) to move slightly along the Z direction through the transmission component (62).

8. A 3D printer with a layer thickness adjustment control mechanism according to claim 1 or 7, characterized in that: The 3D printer also includes a material output adjustment component, which is electrically connected to the controller. When the controller controls the layer thickness adjustment execution component (60) to change the relative distance between the print head (30) and the print platform (63), the controller synchronously adjusts the material output of the material output adjustment component to match the compensated layer thickness.

9. A 3D printer with a layer thickness adjustment control mechanism according to claim 4, characterized in that: The controller is also used to record layer thickness deviation data of multiple consecutive layers, and to correct the Z-axis motion parameters and / or output parameters of subsequent printed layers according to the changing trend of layer thickness deviation of multiple consecutive layers.

10. A 3D printer with a layer thickness adjustment control mechanism according to claim 9, characterized in that: The controller is also connected to a display control panel, which is used to display layer thickness detection data, layer thickness deviation value, compensation status and discharge adjustment status, and to input or modify preset layer thickness data, deviation threshold and graded compensation strategy parameters.

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