3D Printer Printhead Test Pattern Formation for Ejector Detection
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Solution Overview
Problem
Three-dimensional object printing systems face challenges in identifying and correcting inoperative ejectors during the printing process, leading to substandard output and wasted resources due to the inability to assess ejector functionality in real-time.
Innovation Solution
A three-dimensional object printer system that forms test patterns using build and support materials, allowing for the identification of inoperative ejectors through scanned image data analysis, enabling real-time correction and minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the printing operation continues without interruption to complete the object, then the productivity is maintained, but the quality deteriorates due to undetected inoperative ejectors
Solution Approach 1:
The system performs preliminary detection of ejector functionality by forming test patterns at the beginning of the printing operation. This allows identification of inoperative ejectors before they compromise the quality of the main object, enabling early intervention while maintaining overall productivity.
Solution Approach 2:
The system implements continuous feedback by periodically forming test patterns during the printing operation and using image sensors to detect ejector performance. This real-time feedback enables dynamic adjustment of the printing process to maintain quality without sacrificing productivity.
2Manufacturing precision
If the printing operation is stopped to inspect ejector functionality, then the quality is maintained, but the productivity decreases due to interruption
Solution Approach 1:
The system performs self-diagnosis by automatically forming test patterns and detecting ejector functionality during normal printing operations. This eliminates the need for external inspection or interruption, as the system monitors its own ejector performance continuously without affecting productivity.
Solution Approach 2:
The system merges the quality inspection function with the normal printing operation by integrating test pattern formation into the printing process itself. This combination allows simultaneous production and detection, eliminating the need for separate inspection steps that would reduce productivity.
3Measurement precision
If test patterns are formed continuously during printing, then the detection precision is improved, but the productivity decreases due to additional printing steps
Solution Approach 1:
The system performs partial detection by forming test patterns only in specific regions and at selected intervals during printing, rather than continuously across the entire build area. This partial action provides sufficient detection precision for identifying inoperative ejectors while minimizing the impact on overall printing productivity.
4Productivity
If the printhead is corrected during printing, then the productivity is maintained, but the device complexity increases due to additional correction mechanisms
Solution Approach 1:
The system replaces complex mechanical correction mechanisms with a simpler computational approach. By using image sensors to detect ejector misalignment and software algorithms to identify and compensate for inoperative ejectors, the system achieves correction functionality without adding complex mechanical components.
Data Source
AI summary
A three-dimensional object printer ejects drops of a build material from a plurality of ejectors in a first printhead to form an object on a first region of a member and ejects drops of a support material from a plurality of ejectors in a second printhead to support the object on the first region of the member. The second printhead ejects drops of the support material onto a second region of the member that is separate from the first region to form a substrate layer. The first printhead ejects drops of the build material onto the substrate layer to form a printed test pattern. An image sensor generates image data of the printed test pattern to identify an inoperable ejector in the first printhead.