3D Printer Ejector Selection for Color and Hardness
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Solution Overview
Problem
Conventional three-dimensional object printing systems require a large number of build materials and ejectors to achieve full color and varying material properties, leading to high costs and hardware complexity.
Innovation Solution
A method and system that selects specific ejectors based on hardness and color identifiers to form inner and outer layers of an object using different materials, allowing for full color and varying hardness without a substantial increase in the number of materials or hardware, by using a controller to operate a plurality of ejectors configured to eject different materials towards a platen.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional three-dimensional object printing system uses six different build materials (cyan, yellow, magenta, black, white, clear) to print full color objects, then full color capability is achieved, but the number of required materials and ejectors increases substantially when material property variations (e.g., hardness levels) are added
Solution Approach 1:
The patent segments the material property variations into discrete levels (e.g., six hardness levels) and assigns each level to a specific ejector position in the array. This allows the system to offer multiple material properties without requiring a complete set of materials for each property level, thereby reducing the total number of materials needed while maintaining versatility.
Solution Approach 2:
The patent implements local quality by allowing different regions of the printed object to have different material properties based on the selected hardness identifier. The controller selectively activates specific ejectors within the array to deposit materials with appropriate local properties, enabling full color and variable hardness without requiring all material combinations throughout the entire object.
2Adaptability or versatility
If a printing system is enabled to print three-dimensional objects in full color and with six variations in hardness, then comprehensive material property options are provided, but the cost of the printing system becomes very high
Solution Approach 1:
The patent makes each ejector in the array multi-functional by configuring them to handle different material types (e.g., waxy, sandy, gritty) based on the selected hardness identifier. This universal approach allows a single ejector array to serve multiple material property requirements, eliminating the need for separate ejector sets for each hardness level and significantly reducing system cost.
Solution Approach 2:
The patent changes the material parameter (hardness) by selecting from a limited set of base materials with different inherent properties. The controller adjusts which ejectors are activated based on the desired hardness level, enabling the system to provide six variations in hardness using the same physical hardware, thereby avoiding the high costs associated with duplicating the entire material and ejector infrastructure.
3Adaptability or versatility
If multiple ejectors are used to provide different material properties, then material property options increase, but the hardware complexity increases
Solution Approach 1:
The patent implements dynamics by making the ejector array reconfigurable through software control. The controller can dynamically select and activate specific ejectors based on the desired material properties for each printing job. This dynamic configuration allows the system to adapt to different hardness requirements without physical reconfiguration, reducing hardware complexity while maintaining versatility.
Solution Approach 2:
The patent introduces a controller as an intermediary between the user's material property requirements and the physical ejector array. The controller translates the desired hardness identifier into specific ejector activation patterns, managing the complexity of coordinating multiple ejectors with different material properties. This intermediary layer simplifies the user interface and reduces the apparent hardware complexity by abstracting the coordination logic.
Data Source
AI summary
A method of manufacturing a three-dimensional object comprises: selecting a first ejector in a plurality of ejectors of a three-dimensional object printer with reference to a hardness identifier, the first ejector configured to eject a first material; selecting a second ejector in the plurality of ejectors with reference to a color identifier, the second ejector configured to eject a second material having a hardness that is different than a hardness of the first material; operating the first ejector to eject the first material toward a platen to form an inner portion of the object with the first material; and operating the second ejector to eject the second material toward the platen to form an outer layer of the object with the second material, the outer layer of the object surrounding at least a portion of the inner portion of the object.