Installation and alignment of curved parts within a 3D printer

Abstract

This solution addresses the issue of misalignment between print heads, which becomes a problem in 3D printers using multiple print heads as precision requirements increase. [Solution] The 3D printing system comprises a print head, a print head carriage, a horizontal movement mechanism, a print head mount, multiple bends, and an adjustable actuator. The print head mount is configured to receive the print head. The multiple bends connect the print head mount to the print head carriage. The adjustable actuator is configured to engage and position the print head mount within a range of motion in which the multiple bends are subjected to continuous bending stress against a fixed geometric shape.

Description

Cross - reference to related applications

[0001] This non - provisional patent application claims priority to U.S. Provisional Patent Application No. 63 / 725,246, titled "FLEXURE MOUNTING AND ALIGNMENT WITHIN A THREE - DIMENSIONAL PRINTER" by Michael E. Jones et al., filed on November 26, 2024, which is incorporated herein by reference under 35 U.S.C. 119(e).

Technical Field

[0002] This disclosure relates to apparatuses and methods for creating solid three - dimensional (3D) articles by the selective deposition of materials from a print head. More particularly, this disclosure relates to an accurate and easy way to provide precise mechanical alignment between two or more print heads.

Background Art

[0003] For purposes such as prototyping and manufacturing, the use of three - dimensional (3D) printers has been increasing rapidly. One type of 3D printer selectively deposits materials using an inkjet print head to form a three - dimensional (3D) manufactured article. The print head scans along a "scanning axis" to selectively and repeatedly form layers, and these layers cumulatively define a three - dimensional (3D) manufactured article. In some embodiments, each layer is capable of being cured by ultraviolet light. In other embodiments, phase - change ink is used. As is known in the art, the term "ink" includes both the shaping material and the support material.

Summary of the Invention

Problems to be Solved by the Invention

[0004] One problem is 3D printers that utilize multiple print heads. As accuracy requirements increase, misalignment between print heads can become a more significant issue.

Means for Solving the Problems

[0005] In the first subject of this disclosure, a three-dimensional (3D) printing system is defined by mutually orthogonal axes including the X, Y, and Z axes. The 3D printing system is configured to manufacture a 3D article and comprises a print head, a print head carriage, a horizontal movement mechanism, a print head mount, a plurality of bends, and an adjustable actuator. The print head includes a nozzle array positioned along the Y axis and configured to eject material droplets along the Z axis to form layers of a 3D article. The horizontal movement mechanism is configured to provide relative scanning motion between the print head carriage and the 3D article along the X axis. The print head mount is configured to receive and mount the print head. The plurality of bends connect the print head mount to the print head carriage. The adjustable actuator is configured to engage and position the print head mount within a range of motion in which the plurality of bends are subjected to continuous bending stress against a fixed geometric shape.

[0006] In one implementation configuration, the print head mount rotates around the Z-axis by adjusting an adjustable actuator. Multiple bends may include two bends where the main axes are either not parallel to each other or perpendicular to each other.

[0007] In another implementation, the print head mount is displaced along the Y-axis by adjusting an adjustable actuator. Multiple bends may include two bends parallel to the main axis. The two bends can be connected to both sides of the print head mount with respect to the Y-axis.

[0008] In the second subject of this disclosure, a three-dimensional (3D) printing system is defined by mutually orthogonal axes including the X, Y, and Z axes. The three-dimensional (3D) printing system is configured to manufacture three-dimensional (3D) articles. The 3D printing system comprises: (1) a print head carriage; (2) a first print head mount supporting a first print head having a first nozzle array arranged along the Y axis; (3) a first pair of bends connecting the first print head mount to the print head carriage, which are subjected to bending stress over a first rotational position range about the Z axis; (4) a first adjustable actuator configured to adjust the rotational position; (5) a second print head mount supporting a second print head having a second nozzle array arranged along the Y axis; (6) a second pair of bends connecting the second print head mount to the print head carriage, which are subjected to bending stress over a second position range along the Y axis; and (7) a second adjustable actuator configured to adjust the position along the Y axis.

[0009] In one implementation configuration, the first pair of bent portions has a first pair of principal axes that are orthogonal to each other.

[0010] In another implementation, the second pair of bent sections has a second pair of principal axes that are parallel to each other. [Brief explanation of the drawing]

[0011] [Figure 1] Schematic diagram of a 3D printing system configured to manufacture three-dimensional (3D) objects. [Figure 2] Schematic cross-sectional view of a piezoelectric drop ejector [Figure 3A] Schematic layout diagram of a printhead carriage that transports two printheads, including the first and second printheads. [Figure 3B] This figure is similar to Figure 3A, except that it shows the mechanical misalignment between the print heads. [Figure 4]A single perspective view of a printhead carriage equipped with two printheads. [Figure 5] Perspective projection of the first print head mount connected to the first pair of two bent sections. [Figure 6] A top view of the carriage with two printheads mounted, highlighting the alignment mechanism for adjusting the theta-Z orientation of the first of the two printheads. [Figure 7] Perspective view of the second print head mount connected to the second pair of two bent sections. [Figure 8] A top view of a carriage with two printheads, highlighting the alignment mechanism for adjusting the linear position of the second of the two printheads along the Y-axis. [Figure 9] A flowchart illustrating how to mechanically mount and position two printheads within a carriage. [Figure 10] Flowchart showing how to manufacture 3D objects [Modes for carrying out the invention]

[0012] Figure 1 is a schematic diagram of a three-dimensional (3D) printing system 2 configured to manufacture a three-dimensional (3D) object 4. In describing the printing system 2, mutually orthogonal axes X, Y, and Z can be used (though not shown in Figure 1). Axes X and Y can be referred to as the “lateral” or “horizontal” axes, and Z can be described as the “vertical” axis. However, it should be understood that Z does not necessarily coincide with gravity. Also, X refers to the “scanning” axis, and Y refers to the “lateral” axis. In some embodiments, the +Z direction generally refers to the “upward” direction, and -Z generally refers to the “downward” direction. “Downward” indicates the direction of gravity. Furthermore, when describing relative directions such as “orthogonal,” it should be understood that this is generally within the manufacturing tolerances in the design. Therefore, depending on the system, there may be deviations of 1, 2, or more degrees from orthogonality.

[0013] In describing the various components of System 2, the terms principal axis, intermediate axis, and minor axis may be used. These axes are generally orthogonal, and the terms indicate relative size. For example, a beam with a rectangular cross-section has a length defined along the principal axis, which is greater than its width. The beam has a width defined along the intermediate axis, which is greater than its thickness defined along the minor axis.

[0014] The build plate 6 is configured to support the 3D article 4 to be formed or manufactured. A vertical movement mechanism 8 is mechanically connected to the build plate 6 and is configured to position and move the build plate 6 vertically. In one embodiment, the vertical movement mechanism 8 includes a motor, a lead screw, and a nut. The nut is connected to move vertically with the build plate 6. The motor is rotationally connected to the lead screw, which is screwed into the nut. The motor may be a stepper motor. As the motor rotates the lead screw, the build plate is raised and lowered along the vertical Z axis. An alternative vertical movement mechanism 8 may include a rack and pinion system. The rack is a linear gear connected to the build plate. The pinion is a circular gear connected to the motor and engaged with the linear gear. As the motor rotates the pinion, the build plate is raised and lowered. Yet another alternative mechanism may include an electric belt connected to the build plate. All of these vertical movement mechanisms 8 are known in the art for imparting motion along various axes (including X, Y, Z, and diagonal axes) in a 3D printing system and can be used in the vertical movement mechanisms 8 and / or horizontal movement mechanisms 14 described later.

[0015] A drop-on-demand piezo (DODP) printhead 11 mounted on a printhead carriage 10 is fluidically connected to a supply unit 12 that contains and supplies phase-change ink. The supply unit 12 and the printhead 10 include a heating element configured to maintain the ink in a liquid state. The heating element may be a resistive heating element that includes a resistor connected to a power supply. The supply unit 12 may include a resistive heated bottle or container that contains the phase-change ink. The resistive heating element may be incorporated into the container. The supply unit 12 may include a flexible tube that fluidically connects the container to the printhead 10. The resistive heating element may be wrapped around the tube. The supply unit 12 and the printhead 10 may also include thermocouples or other temperature sensors to enable closed-loop temperature control.

[0016] In some embodiments, the phase-change properties of the ink are provided by the inclusion of a wax component. The wax component may include one or more hydrocarbon waxes, fatty alcohol waxes, fatty acid waxes, fatty acid ester waxes, aldehyde waxes, amide waxes, and ketone waxes. The wax component may provide 50–80 mass percent or 60–70 mass percent of the ink. Other ranges are also possible.

[0017] The ink may also contain a “tackifier” in the range of 5 to 50 mass percent. The tackifier is a resin added to improve the immediate adhesion or tackiness of the ink to a surface. The ink may also contain monomers and / or oligomers as well as a catalyst. The catalyst can induce polymerization and / or crosslinking within the monomers and / or oligomers when irradiated with radiation having spectral peaks in the range of blue to ultraviolet (100 to 500 nanometers or nm). Typically, phase-change inks containing monomers / oligomers and catalysts are “forming material” inks for forming 3D articles, while inks without monomers / oligomers and catalysts are “supporting material” inks used as a base for the overhanging structure of the forming material.

[0018] The printhead carriage 10 and / or the shaping plate 6 are mechanically connected to the horizontal movement mechanism 14. The horizontal movement mechanism 14 is configured to impart relative lateral or horizontal movement between the printhead and the shaping plate 8. This includes scanning the printhead along the scanning axis X with respect to the shaping plate 6. When referring to "scanning of the printhead 10", the scanning movement may be a movement of the printhead along the X-axis or a movement of the shaping plate along the X-axis. If the printhead is a "full-width" printhead, a single-axis movement is required. If the printhead has a partial width of the area to be printed, the printing is performed over a wide area, and a relative movement along the Y-axis is used to enable complete printing of the required area.

[0019] In the case of single-axis movement (along X), the horizontal movement mechanism 14 includes a single linear motor or stepper motor that drives a lead screw, a gear train, a rack and pinion, a belt pulley, or other mechanism that moves the shaping plate 6 or the printhead along the X-axis. In the case of two-axis movement along X and Y, the horizontal movement mechanism 14 can include a stacked structure of two orthogonal linear motors or stepper motors that move the shaping plate 6 or the printhead along X and Y. In yet another embodiment, the horizontal movement mechanism 14 can include an X motor that moves the printhead and a Y motor that moves the shaping plate 6. All such variations of the horizontal movement mechanism 14 are known in the art for 2D and 3D printing. In some embodiments, the horizontal movement mechanism 14 operates on the same principle as, or utilizes a very similar mechanism to, the vertical movement mechanism 8.

[0020] The print head has an array of piezo actuators 16 (Figure 2) configured to eject ink droplets downward and selectively applies material to the upper surface 18 of the 3D article 4 (or the upper surface 18 of the shaping plate in the initial stage). Hereinafter, the component 18 is referred to as the "upper surface". The component 18 is shown to be located at the same vertical height as the "shaping plane" 19, which is the area on which the ink droplets are selectively applied to pixel positions or pixels. A "pixel" forms a rectangular dot matrix pattern that is selectively treated or printed with ink droplets. Pixels and rectangular dot matrix patterns are known in the art for 2D and 3D printing.

[0021] The controller 20 is connected to the vertical movement mechanism 8, the print head carriage 10, the phase change ink supply device 12, and the horizontal movement mechanism 14. The controller 20 includes a processor connected to an information storage device. The information storage device stores software instructions that, when executed by the processor, control various parts of the 3D printing system 2. In various embodiments, the controller 20 may be referred to as a computer, a microcontroller, or a server (shared) computer. The controller 20 is programmed to operate the components of the printing system 2 to form the 3D article 4 in a layer-by-layer manner.

[0022] Figure 2 is a schematic diagram of an embodiment of a piezoelectric drop ejector 16, which may be part of a printhead 11. The ejector 16 includes a fluid manifold 22 that supplies liquefied phase-change ink to an array of pressure chambers 24, one of which is shown in cross-section. A piezoelectric element 26 is coupled to a thin film 28. The piezoelectric element 26 changes size in response to the reception of an electrical pulse, thereby contracting the thin film 28. The contraction of the thin film 28 temporarily generates a pressure pulse within the chamber 24, thereby ejecting droplets of liquefied phase-change ink from the nozzle 30. In this exemplary embodiment, the piezoelectric drop ejector 16 may be formed from etched silicon 32, or from deposited thin films 34 of metal, glass, and ceramic. In other embodiments, the piezoelectric drop ejector 16 may be formed from laminated layers of metal and glass. In some embodiments, the piezoelectric drop ejector 16 may be formed from laminated stainless steel sheets.

[0023] One example of a piezoelectric printhead is the Xerox® "M-Series Industrial Inkjet Jetstack." Jetstack printheads are formed from at least partially stainless steel layers and are resistant to a wide range of chemicals. Other piezoelectric printheads are also available, including those manufactured by companies such as Ricoh, Zaar, Panasonic, Seiko Instruments, and Seiko Epson.

[0024] Other printheads can also be used in System 2. These may be based on other ejector configurations, such as thermal inkjet printers that operate by pulse-driving a heating resistor. Even more printheads with other mechanisms for ejecting droplets of the build material can also be used.

[0025] Figure 3A is a schematic arrangement diagram of a printhead carriage 10 that houses two printheads 11, including a first printhead 11A and a second printhead 11B. The first printhead 11A and the second printhead 11B each contain a first array 36A and a second array 36B of nozzles 30, respectively. The nozzle arrays 36A and 36B are arranged along the lateral Y-axis. A horizontal movement mechanism 14 is configured to provide relative motion between the nozzle arrays 36A and 36B and the build plane 19. As the nozzles 30 pass through the build plane, material droplets 38 are selectively deposited. Figure 3A shows a case of good or ideal alignment between material droplets 38A deposited by the first printhead 36A and material droplets 38B deposited by the second printhead 36B. This requires high-precision mechanical linear alignment along the Y-axis, mechanical rotational alignment around the vertical Z-axis, and software (droplet timing) alignment along the scanning axis X.

[0026] Alignment along X can be achieved by printing a test pattern and then iteratively varying the ejection timing of the material droplets 38. This can be done manually or automatically. Methods for manually or automatically aligning the material droplets 38 along the scanning axis are known in inkjet printing technology.

[0027] The misalignment between the two print heads 11A and 11B is shown in Figure 3B. This is exaggerated for clarity. The illustrated misalignment includes theta-Z (rotation around the Z axis, which appears as an oblique angular error in the XY plane for the two arrays of material droplets 38). The illustrated misalignment also includes a linear Y-axis error.

[0028] Figure 4 is a perspective view of one embodiment of the print head carriage 10. The print heads 11A and 11B are installed within the carriage 10 and are included in the carriage 10. In one embodiment, the horizontal movement mechanism 14 is configured to scan the print head carriage 10 along the X-axis on the build plane 19. The print heads 11A and 11B each have nozzle arrays 36A and 36B, respectively, which are arranged independently along the Y-axis. The nozzle arrays 36A and 36B are configured to eject material droplets 38A and 38B in the -Z direction.

[0029] Figure 5 is a perspective view of a first print head mount 40 connected to a pair of bends 42X and 42Y (or the components 42 together referred to as a first pair of bends or a plurality of bends 42). The first print head mount 40 includes mounting holes 44 for mechanically attaching a first print head 11A to the first print head mount 40. The pair of bends 42 includes a bend mount 46 for connecting the pair of bends 42 to the print head carriage 10. Thus, the pair of bends 42 connects the first print head mount 40 (and therefore the first print head 11A) to the print head carriage 11A.

[0030] The bent section 42X has a main axis (length) along the X axis, an intermediate axis (width) along the Z axis, and a secondary axis (thickness) along the Y axis. The bent section 42Y has a main axis along the Y axis, an intermediate axis (width) along the Z axis, and a secondary axis (thickness) along the X axis. Therefore, the main axes of the bent sections 42X and 42Y are orthogonal and intersect at the mount 46.

[0031] Figure 6 is a top view of the carriage 10 to which the print heads 11A and 11B are mounted, with an emphasis on the theta-Z alignment mechanism 48, which includes the bend pair 42 and the adjustable actuator 50. The first print head 11A is firmly mounted to the first print head mount 40. The bend mount 46 is firmly connected to the carriage 10 near the center of rotation 52. The adjustable actuator 50 is configured to press against the print head mount 40 at the end of the bend 42Y opposite to the bend mount 46 with respect to the Y axis.

[0032] In the illustrated embodiment, the first adjustable actuator 50 restrains the angular position of the print head mount 40 with respect to a vertical axis (parallel to the Z-axis) passing through the rotation center 52. As shown in the illustration, the bent portion pair 42 has bending stress, which generates a force between the adjustable actuator 50 and the print head mount 40. The bending stress of the bent portion pair 42 fixes the theta-Z position of the print head mount 40 with respect to the rotation center 52.

[0033] The adjustable actuator 50 is rotatably mounted at a fixed end 54 and has a fine-threaded screw 56 at the opposite end 58, allowing for fine adjustment of the theta-Z position by rotating the fine-threaded screw 56. In this embodiment, the adjustment is performed manually. In other embodiments, the first adjustable actuator 50 may be motorized and include a reduction motor for adjusting the threaded screw, which acts on the print head mount 40. Throughout the entire adjustment range of the first adjustable actuator 50, the bent pair is under bending stress.

[0034] Figure 7 is a perspective view of a second printhead mount 60 connected to a second pair of bends or a plurality of bends 62. The second printhead mount 60 includes mounting holes 64 for mechanically attaching the second printhead 11B to the second printhead mount 60. Each pair of bends 62 is individually provided with a bend mount 66 for connecting the pair of bends 62 to the printhead carriage 10. Thus, the pair of bends 62 connects the first printhead mount 60 (and therefore the second printhead 11B) to the printhead carriage 11A.

[0035] Each pair of bends 62 has a main axis (length) along the X-axis, an intermediate axis (width) along the Z-axis, and a secondary axis (thickness) along the X-axis. The pairs of bends 62 are parallel and connected to opposing ends of the print head mount 60 with respect to the Y-axis.

[0036] Figure 8 is a top view of the carriage 10 on which print heads 11A and 11B are mounted, with emphasis on the Y-alignment mechanism 68, which includes the bend pair 62 and the adjustable actuator 70. The second print head 11B is firmly mounted to the second print head mount 60. The bend mount 66 is firmly connected to the carriage 10. The second adjustable actuator 70 is configured to press against the print head mount 60, applying force along the Y-axis at the end of the bend 62 opposite the bend mount 66 with respect to the X-axis.

[0037] In the illustrated embodiment, the second adjustable actuator 70 restrains the linear position of the print head mount 60 with respect to the Y axis. As shown in the figure, the bent portion pair 62 has bending stress, which generates a force between the second adjustable actuator 70 and the second print head mount 60. The bending stress of the bent portion pair 62 fixes the Y position of the print head mount 60.

[0038] In the illustrated embodiment, the second adjustable actuator 70 is a fine-pitch screw, allowing for fine adjustment of the Y position. In some embodiments, the second adjustable actuator 70 may be a reduction gear to improve adjustment accuracy. In this embodiment, adjustment is manual. In other embodiments, the second adjustable actuator 70 may be motorized and include a reduction motor for adjusting a threaded screw, which acts on the print head mount 60. Throughout the full adjustment range of the second adjustable actuator 70, the bent portion pair 62 is under bending stress.

[0039] The bent sections 42 and 62 can be formed from an elastic metal such as stainless steel or a metal alloy. The type and hardness of the metal or alloy can be selected to provide sufficiently high bending stress to offer an adjustable range of motion and stability. The bent sections 42 and 62 can be attached to the print head mounts 40 and 60 by machine screws or welding.

[0040] Figure 9 is a flowchart of a method 100 for mechanically mounting and aligning the print head 11 in the 3D printing system 2. According to 102, the first print head 11A is mounted and secured to the first print head mount 40. Securement includes screwing in and tightening screws, or other methods for forming a firm mechanical connection between the first print head 11A and the first print head mount 40.

[0041] According to 104, the second print head 11B is mounted and secured to the second print head mount 60. This securing includes screwing in and tightening screws, or other methods that form a firm mechanical connection between the second print head 11B and the second print head mount 60.

[0042] According to 106, the first adjustable actuator 50 is operated to align the first print head 11A with respect to the second print head 11B at an angle (theta-Z). An embodiment of step 106 includes the steps of first printing a test plot and then determining the amount of angle adjustment based on angle error measurement. Step 106 is repeatable and includes: (1) generating a test plot; (2) determining the angle error around the Z axis by measuring the angle error on the test plot; (3) determining how much to adjust the first adjustable actuator based on the measurement; (4) adjusting the first adjustable actuator based on (3); and then repeating (1) to (4) until the angle error falls below a predetermined threshold.

[0043] According to 108, the second adjustable actuator 70 is operated to linearly (along the Y axis) align the second print head 11B with respect to the first print head 11A. An embodiment of step 108 includes the steps of first printing a test plot and then determining the amount of linear adjustment based on angular error measurements. Step 108 is repeatable and includes: (1) generating a test plot; (2) determining the linear error along the Y axis by measuring the placement comparison on the test plot; (3) determining how much to adjust the second adjustable actuator 70 based on the measurements; (4) adjusting the second adjustable actuator 70 based on (3); and then repeating steps (1) to (4) until the linear error falls below a predetermined threshold.

[0044] In addition to the steps shown in Figure 9, method 100 may also include correction of positional misalignment in X. With respect to steps 106 and 108, the process is iterative and includes: (1) generating a test plot; (2) identifying a linear error along the X axis by measuring the placement comparison on the test plot; (3) determining how much to adjust the droplet timing between print heads 11A and 11B based on the measurements; (4) adjusting the droplet timing (3); and then repeating (1) to (4) until the linear error falls below a predetermined threshold.

[0045] Steps 108 and 106 can be performed in reverse order (108 before 106) or simultaneously. Correction of positional misalignment in X can also be performed before, after, or simultaneously with one or more steps 106 and 108.

[0046] Figure 10 is a flowchart of a method 200 for manufacturing a 3D item 4 using a 3D printing system 2. According to 202, the vertical movement mechanism 8 is operated to position the top or top surface of the 3D item 4 (or build plate 6 in the initial state) on the build plane 19.

[0047] According to 204A, the horizontal movement mechanism 14 is operated to provide relative horizontal movement between the print head carriage 10 and the build plane 19 along the scanning axis X. According to 204B, in parallel with 204A, the print head 11 is operated to eject a dot matrix pattern of material droplets, selectively forming a new material layer on the build plane 19. As part of 204A / B, the horizontal movement mechanism positions the print head carriage 10 along the Y axis, allowing for multiple scans to fully process the build plane 19. Steps 203 and 204A / B are repeated to complete the formation of the 3D article 4.

[0048] The specific embodiments and their applications described above are for illustrative purposes only and do not preclude any changes or modifications that fall within the scope of the following claims. For example, this description describes an implementation for two printheads. However, certain claims are also applicable to a single printhead or two or more printheads. In particular, a claim may describe a first and a second element. This does not preclude a third element or any number of elements.

Claims

1. A three-dimensional (3D) printing system defined by mutually orthogonal axes including the X, Y, and Z axes, A print head having a nozzle array positioned along the Y-axis and configured to eject material droplets along the Z-axis to form layers of a 3D object; Printhead carriage; A horizontal movement mechanism configured to impart relative scanning motion between the print head carriage and the 3D object along the X-axis; A print head mount configured to receive and mount the aforementioned print head; Multiple bent portions connecting the print head mount to the print head carriage; An adjustable actuator configured to engage and position the print head mount within a range of motion in which the multiple bent portions are subjected to continuous bending stress on the fixed geometric shape. A three-dimensional (3D) printing system equipped with [the following features].

2. The three-dimensional (3D) printing system according to claim 1, characterized in that the print head mount rotates about the Z axis by adjusting the adjustable actuator.

3. The three-dimensional (3D) printing system according to claim 2, characterized in that the plurality of bent portions include two non-parallel bent portions.

4. The three-dimensional (3D) printing system according to claim 1, characterized in that the print head mount is displaced along the Y axis by adjusting the adjustable actuator.

5. The three-dimensional (3D) printing system according to claim 4, characterized in that the multiple bends include two bends connected to both sides of the print head mount with respect to the Y axis.

6. The print head includes a first print head and a second print head; The first print head includes a first nozzle array, and the second print head includes a second nozzle array; The print head mount includes a first print head mount and a second print head mount, each configured to receive the first print head and the second print head, respectively; The adjustable actuator includes a first adjustable actuator and a second adjustable actuator, each configured to engage and position the first and second print head mounts, respectively. A three-dimensional (3D) printing system according to claim 1, characterized in that it is the same as described in claim 1.

7. The three-dimensional (3D) printing system according to claim 6, characterized in that the first adjustable actuator is configured to rotate and position the first print head mount about the Z axis and to make the first nozzle array and the second nozzle array parallel.

8. The three-dimensional (3D) printing system according to claim 6, characterized in that the second adjustable actuator linearly positions the second print head mount along the Y axis and aligns the first and second nozzle arrays along the Y axis.

9. The three-dimensional (3D) printing system according to claim 7, characterized in that the second adjustable actuator linearly positions the second print head mount along the Y axis and aligns the first and second nozzle arrays along the Y axis.

10. The three-dimensional (3D) printing system according to claim 6, characterized in that the first print head mount is attached to the print head receiver by a pair of bent portions having principal axes extending perpendicular to each other.

11. The three-dimensional (3D) printing system according to claim 6, characterized in that the second print head mount is attached to the print head carriage by a pair of bent portions having principal axes that are parallel to each other and spaced apart with respect to the Y axis.

12. The system further comprises a vertical movement mechanism and a controller, the controller being, (1) Operate the vertical movement mechanism to position the upper surface of the 3D object on the build plane; (2) Operate the horizontal movement mechanism to give the print head carriage a scanning motion across the build plane; (3) Operate the print head to eject a dot matrix pattern of material droplets and form a new material layer on the build plane; and (4) Repeat steps (1) to (3) to complete the formation of the 3D article. The three-dimensional (3D) printing system according to claim 6, characterized in that it is configured as described above.

13. A three-dimensional (3D) printing system defined by mutually orthogonal axes including the X, Y, and Z axes, wherein the three-dimensional (3D) printing system is configured to manufacture 3D articles. Printhead carriage; A horizontal movement mechanism configured to impart relative scanning motion between the print head carriage and the 3D object along the X-axis; A first print head mount supporting a first print head having a first nozzle array arranged along the Y-axis; A first pair of bent portions connecting the first print head mount to the print head carriage, the first pair of bent portions receiving bending stress over a first range of rotational positioning about the Z axis; A first adjustable actuator configured to adjust the rotational position; A second printhead mount supporting a second printhead having a second nozzle array arranged along the Y-axis; A second pair of bends connecting the second print head mount to the print head carriage, the second pair of bends receiving bending stress over a second range of positioning along the Y axis; and A second adjustable actuator configured to adjust the position along the Y-axis. A three-dimensional (3D) printing system equipped with [the following features].

14. The three-dimensional (3D) printing system according to claim 13, characterized in that the first pair of bent portions has a first pair of principal axes that are orthogonal to each other.

15. The three-dimensional (3D) printing system according to claim 13, characterized in that the second pair of bent portions has a second pair of principal axes parallel to each other.

16. The three-dimensional (3D) printing system according to claim 14, characterized in that the second pair of bent portions has a second pair of principal axes parallel to each other.

17. A method for manufacturing a three-dimensional (3D) article, A process for constructing a three-dimensional (3D) printing system, wherein the three-dimensional (3D) printing system is as follows: A print head having a nozzle array primarily positioned along the horizontal Y-axis and configured to eject material droplets along the vertical Z-axis to form layers of a 3D object; Printhead carriage; Horizontal movement mechanism; A print head mount configured to receive and mount the aforementioned print head; Multiple bent portions connecting the print head mount to the print head carriage; An adjustable actuator configured to engage and position the print head mount within a range of motion in which the multiple bent portions are subjected to continuous bending stress on the fixed geometric shape. A process comprising; A step of operating the vertical movement mechanism to position the upper surface of the 3D object on the build plane; A step of operating the horizontal movement mechanism to provide a relative scanning motion between the print head receiver and the 3D object along the horizontal X-axis perpendicular to the Y-axis; and Simultaneously with the operation of the horizontal movement mechanism, the print head is operated to eject droplets and form a dot matrix pattern across the build plane. Methods that include...

18. The print head includes a first print head and a second print head; The first print head includes a first nozzle array, and the second print head includes a second nozzle array; The print head mount includes a first print head mount and a second print head mount, each configured to receive the first print head and the second print head, respectively; The adjustable actuator includes a first print head actuator and a second print head actuator, each configured to engage and position the first print head mount and the second print head mount, respectively; The method includes the step of operating the adjustable actuator to align the first and second print heads by rotating them with respect to the Z axis and linearly with respect to the Y axis. The method according to claim 17, characterized in that

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