3D Printer Perimeter Control for Quantization Error Distribution

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Solution Overview

Problem

Three-dimensional (3D) object printers that eject discrete material drops face issues with local anomalies and incorrect part height due to inconsistent drop spacing, leading to deformities and structural instability, especially when forming perimeters in parts with small numbers of drops per perimeter.

Innovation Solution

A method and apparatus for a 3D object printer that distributes quantization errors across layers by modifying machine-ready instructions to adjust the number and placement of material drops, using a controller to identify the number of drops and their location for forming perimeters, and employing a blue noise generator to decorrelate phase variations, ensuring accurate drop spacing and material distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If discrete material drops are used to form perimeters in 3D printed objects, then the manufacturing process becomes digitalizable and controllable, but quantization errors cause local anomalies and incorrect part height

Engineering Contradiction:

Improvedigitalizability of printing processVSAvoidperimeter accuracy and part height

Core Design Contradiction:

Extent of automationVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by calculating and distributing quantization errors in advance during the slicing process. The system computes the expected quantization error for each layer based on the perimeter length and drop spacing, then proactively adjusts the number of drops in subsequent layers to compensate for accumulated errors before they manifest as physical deformities. This predictive error distribution prevents local anomalies and height inaccuracies before they occur during actual printing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements feedback through an error tracking and compensation mechanism. The system continuously monitors the cumulative quantization error across layers and uses this feedback to dynamically adjust the number of drops in each subsequent layer. This closed-loop control ensures that errors are distributed evenly throughout the object rather than accumulating locally, maintaining manufacturing precision while using discrete digital drops.

Inventive Principle:

Principle #23Feedback

2Productivity

If the number of drops per perimeter is reduced to speed up printing, then productivity increases, but drop spacing errors become more significant causing deformities

Engineering Contradiction:

Improveprinting speedVSAvoiddrop spacing accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies parameter changes by dynamically adjusting the number of drops parameter based on the calculated quantization error for each layer. Instead of using a fixed drop spacing that may cause errors, the system varies the number of drops in each perimeter layer to compensate for accumulated positioning errors. This adaptive parameter adjustment maintains manufacturing precision even when printing speed is increased by reducing overall drop count.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If standard drop spacing is used for all perimeter layers, then the printing process is simple and fast, but quantization errors accumulate causing local part deformity

Engineering Contradiction:

Improvesimplicity of printing processVSAvoidstructural uniformity

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The patent applies segmentation by dividing the printing process into individual layers with independent error compensation. Each layer's perimeter is treated as a separate segment where quantization errors are calculated and compensated independently. This segmentation allows the system to maintain simple standard drop spacing within each layer while distributing errors across different layers, preventing local accumulation and maintaining structural uniformity throughout the entire object.

Inventive Principle:

Principle #1Segmentation

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 approach ensures that the quantization error is distributed across layers, making it imperceptible and maintaining part integrity by preventing error accumulation, thereby improving the structural stability and accuracy of perimeter formation in 3D printed objects.

Implementation Method 1

An electrical current is passed through the conductor to produce an electromagnetic field that causes the meniscus of the melted metal at a nozzle of the chamber to separate from the melted metal within the chamber and be propelled from the nozzle

Methodology Applied

Scientific EffectElectromagnetic field: Electromagnetic Induction

Data Source

PatentUS11883881B2System and method for operating a material drop ejecting three-dimensional (3D) object printer to prevent quantization error in perimeters of a three-dimensional printed object

Publication Date: 2024.01.30 XEROX CORP

AI summary

A slicer in a material drop ejecting three-dimensional (3D) object printer determines the number of material drops to eject to form a perimeter in an object layer and distributes a quantization error over the layers forming the perimeter. The slicer also identifies the location for the first material drop ejected to form the perimeter using a blue noise generator.