3D Printer Optical Sensor Arrays for Feature Accuracy
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Solution Overview
Problem
Three-dimensional object printers face issues with inkjet functionality during the printing process, leading to inaccurately formed object features due to inkjet deficiencies, resulting in scrapped products and inefficient printing processes.
Innovation Solution
A system utilizing multiple optical sensor arrays to measure object features in real-time, with light sources and photo detectors, and a controller to move the sensor arrays and light sources relative to the object, enabling continuous monitoring and correction of feature accuracy during printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple optical sensor arrays are added to enable real-time measurement, then measurement precision and detection capability are improved, but device complexity increases
Solution Approach 1:
The measurement system is divided into multiple sensor arrays, each responsible for measuring specific surfaces or features of the object. This segmentation allows comprehensive measurement coverage while maintaining manageable complexity in each individual sensor unit.
Solution Approach 2:
Multiple sensor arrays are positioned at different spatial locations and angles around the printing area, creating a three-dimensional measurement network. This dimensional approach enables complete surface coverage and accurate feature measurement from multiple perspectives simultaneously.
2Manufacturing precision
If multiple sensor arrays are used to monitor all surfaces, then manufacturing precision is improved, but productivity decreases due to increased system complexity
Solution Approach 1:
The optical sensor arrays operate continuously throughout the printing process, providing real-time measurement and monitoring without interrupting the printing operation. This continuous measurement enables immediate detection of deviations while maintaining uninterrupted material deposition.
Solution Approach 2:
The system implements closed-loop feedback by continuously comparing measured features against target specifications and providing real-time information to the control system. This feedback mechanism enables dynamic adjustment of printing parameters to maintain precision without requiring repeated print jobs.
3Reliability
If real-time detection is implemented during printing, then product yield is improved by reducing scrapped objects, but device complexity increases due to additional sensors and actuators
Solution Approach 1:
The system performs preliminary detection of potential defects during the printing process itself, before the object is complete. This early detection allows for corrective action during printing rather than after completion, preventing wasted material and improving yield.
Solution Approach 2:
The printing system performs self-diagnosis and self-correction by using the optical sensor arrays to monitor its own output in real-time and automatically adjusting printing parameters through feedback control, eliminating the need for external inspection equipment.
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
This solution allows for real-time detection and correction of inaccurately formed features, improving product yield and printing efficiency by ensuring proper object formation and reducing the need for restorative procedures.
Implementation Method 1
a plurality of light sources configured to direct light onto surfaces of the object on the substrate, a plurality of optical sensor arrays having a plurality of photo detectors, the optical sensor arrays being configured to generate image data of the surfaces of the object from which the photo detectors receive light
Data Source
AI summary
A three-dimensional object printer generates image data of an object being formed in the printer with a plurality of light sources and a plurality of optical sensor arrays. A controller receives the image data and identifies measurements of the object and of the features of the object. The controller compares the measurements to expected measurements and adds material or removes material from the object in response to the identified measurements being outside a predetermined range about the expected measurements.