3D Printer Layer Deviation for Streak Suppression
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Solution Overview
Problem
Three-dimensional objects formed by existing printers often exhibit streaks parallel to the main scanning direction due to continuous deposition of layers, which affects the object's surface quality and flatness.
Innovation Solution
A method that involves calculating cross-sectional slice information to form layers with print paths intersecting in a second direction, ensuring that boundaries between layers are partly deviated in the second direction, and using nozzle extrusion control to set print paths diagonally or change their width, preventing continuous streaks and achieving a flat surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If layers are deposited by extruding inks along continuous print paths in the main scanning direction, then the three-dimensional object can be formed efficiently, but streaks parallel to the main scanning direction are generated on the surface
Solution Approach 1:
The invention introduces a second direction (sub-scanning direction) to deviate print path boundaries between adjacent layers. Instead of maintaining continuous boundaries in the first direction (main scanning direction) only, the print paths are intentionally offset in the second direction, causing boundaries to intersect and cancel out streak formation while preserving deposition efficiency
Solution Approach 2:
The invention creates asymmetric deviation of print path boundaries between adjacent layers in the second direction. Each layer's print paths are positioned differently relative to the layer below, breaking the symmetry that would otherwise cause continuous streaks to form along the main scanning direction
2Ease of manufacture
If print paths are arranged with boundaries continuous in the deposition direction, then layer deposition is simplified, but streaks are generated affecting surface flatness
Solution Approach 1:
The solution maintains simple layer-by-layer deposition while introducing boundary deviation in the second direction (sub-scanning direction). This adds a dimensional element to boundary positioning that prevents streak formation without complicating the overall deposition process or requiring complex multi-axis coordination
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
The method effectively suppresses the generation of streaks parallel to the main scanning direction, resulting in a smoother and flatter surface of the three-dimensional object, improving the accuracy and quality of the printed object.
Implementation Method 1
a printing step of extruding inks onto a deposited surface to form a single print path extending in a first direction
Data Source
AI summary
[Object] It is an object to provide a method for forming a three-dimensional object that suppresses generation of streaks on the three-dimensional object, which streaks are parallel to a main scanning direction.[Means of Realizing the Object] A method for forming a three-dimensional object includes a slice information calculation step (step ST23) of dividing three-dimensional data of the three-dimensional object into a plurality of layers so as to calculate cross-sectional slice information of each of the layers; and a unit-layer formation step (step ST27) of forming each of the layers based on the cross-sectional slice information. The unit-layer formation step (step ST27) is repeated a plurality of times. The unit-layer formation step (step ST27) includes a printing step (step ST27A) of extruding inks onto a work surface while moving the extruders in the main scanning direction so as to form a single print path. The printing step and a sub-scanning direction movement step (step ST27B) of moving the work surface in a sub-scanning direction are alternately performed. The print paths are formed in such a manner that a boundary between the print paths between each adjacent pair of layers in a deposition direction of the layers is at least partly deviated in the sub-scanning direction.