3D Object Inkjet Printing with Dynamic Nozzle Correction
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Solution Overview
Problem
Inkjet printing methods for three-dimensional objects often result in blurred or wavy print edges on side surfaces due to the reversal of height differences between print nozzle rows, leading to inaccuracies and the need for multi-stage printing processes to achieve sharp edges.
Innovation Solution
A method that corrects print data for inkjet nozzles using correction factors based on a comparison print image, adjusting firing times to compensate for the distance between print lines on both the top and side surfaces of a three-dimensional object, allowing continuous printing with sharp edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing is performed on three-dimensional objects with a print head positioned parallel to the top surface, then printing on the top surface is simple and fast, but the print edges on side surfaces become blurred and wavy
Solution Approach 1:
The print head is tilted at an angle relative to the top surface of the three-dimensional object, creating a dynamic printing geometry that allows simultaneous sharp printing on both top and side surfaces. This angular positioning enables the inkjet system to maintain precise print edges across different surface orientations during continuous printing operation.
Solution Approach 2:
The invention modifies the printing parameters by introducing a tilt angle parameter for the print head relative to the object surface. This parameter change fundamentally alters the printing geometry, allowing the system to compensate for the reversal of height differences between print nozzle rows when printing on side surfaces, thereby maintaining sharp print edges while preserving high printing speed.
2Manufacturing precision
If the print head is tilted to print side surfaces sharply, then print edge sharpness improves, but the printing process becomes more complex
Solution Approach 1:
The invention performs preliminary geometric analysis to determine the specific tilt angle and corresponding correction factors before the actual printing process. By pre-calculating these parameters based on the object's geometry and the desired print quality, the system avoids complex real-time adjustments during printing, thereby maintaining process simplicity while achieving sharp print edges.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the printing process and adjust correction factors based on the actual print quality observed. This feedback loop allows the system to automatically optimize print edge sharpness on side surfaces while maintaining the tilted print head configuration, reducing the need for manual intervention and process complexity.
3Manufacturing precision
If correction factors are applied to print data, then print edge sharpness on side surfaces improves, but processing time increases
Solution Approach 1:
The correction factors are pre-calculated and stored in lookup tables or databases before the printing process begins. During printing, the system simply retrieves the appropriate correction factors based on the object geometry and print nozzle position, rather than calculating them in real-time. This preliminary action significantly reduces processing time while maintaining high print edge sharpness on side surfaces.
Solution Approach 2:
The system applies correction factors selectively only to the portions of the print data that correspond to side surface printing, rather than processing the entire print dataset. By applying corrections only where necessary (on side surfaces rather than top surfaces), the system minimizes processing time while achieving the desired print quality improvement.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous printing with sharply defined edges on both top and side surfaces of three-dimensional objects, ensuring uniform layer thickness and homogeneity, suitable for electronic components requiring electromagnetic interference shielding.
Implementation Method 1
inkjet printing processes can also be used for other purposes. For example, they can be used to apply a functional layer or print pattern to three-dimensional objects
Implementation Method 2
After the ink has been printed onto the surface of the SIP module, the ink is cured, for example, with UV light, to form a continuous functional layer on the surface of the SIP module
Data Source
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AI summary
The present invention relates to an inkjet printing method for continuously printing at least a portion of a top surface 110 and at least a portion of a side surface 120 of a three-dimensional (3D) object 100 with ink.According to the invention, before printing the object 100, the print data for the print nozzles A1 of a first print nozzle row A are corrected with a first correction factor KA and/or the print data for the print nozzles B1 of a second print nozzle row B are corrected with a second correction factor KB, wherein the first correction factor KA and/or the second correction factor KB is/are determined on the basis of a previously generated comparison print image that was previously generated without correction, and wherein the first correction factor KA and/or the second correction factor KB is/are dependent on the distance d of the print line DA generated by the print nozzles A1 of the first print nozzle row A to the print line DB generated by the print nozzles B1 of the second print nozzle row B in the previously generated comparison print image.