3D Printing Head Distance Control for Surface Quality
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Solution Overview
Problem
Conventional inkjet-based three-dimensional object forming methods result in stepped parts with heights equal to the thickness of one ink layer, leading to periodic contour-like patterns on the surface, which degrade the quality of the formed objects.
Innovation Solution
A forming apparatus and method that change the distance between the inkjet heads and the forming platform during the forming operation based on slice data, allowing for fine and discontinuous projections and depressions instead of continuous stepped parts, by performing multiple scans at the same position with varying head-platform distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ink layers are formed and stacked based on slice data in conventional inkjet forming methods, then three-dimensional objects can be formed efficiently, but stepped parts with heights equal to ink layer thickness appear, causing periodic contour-like patterns on the surface that degrade quality
Solution Approach 1:
The patent divides the conventional single-scan-per-layer process into multiple scans per slice data. Each scan deposits a portion of the forming material, and the head-platform distance is adjusted between scans. This segmentation allows the total material accumulation to be distributed across multiple passes, preventing the formation of large stepped parts while maintaining forming efficiency.
Solution Approach 2:
The patent introduces dynamic adjustment of the head-platform distance during the forming process. Instead of maintaining a fixed distance for entire layers, the distance is changed between scans within the same slice data processing. This dynamic adjustment enables fine control over material deposition height, creating fine discontinuous projections and depressions rather than large continuous steps, thereby improving surface quality.
2Shape
If the distance between inkjet heads and forming platform is changed upon completion of each ink layer, then layer-by-layer stacking can be achieved, but large stepped parts are produced at positions between overlapping parts of ink layers, creating visible contour lines
Solution Approach 1:
The patent performs preliminary actions by changing the head-platform distance between scans within the same slice data, before completing the entire layer. This preliminary adjustment prevents the formation of large stepped parts by controlling the deposition height of each scan portion. The distance change is prepared in advance for each scan transition, ensuring that when layers are stacked, the transitions are fine and discontinuous rather than large and continuous, thus improving surface smoothness while maintaining proper layer stacking.
3Manufacturing precision
If multiple scans are performed at the same position with varying head-platform distances, then fine discontinuous projections and depressions are formed instead of large stepped parts, but the process complexity increases
Solution Approach 1:
The patent changes the head-platform distance parameter between scans within the same slice data processing. By varying this physical parameter, the system creates fine discontinuous projections and depressions instead of large stepped parts. This parameter change approach achieves improved surface quality through controlled variations in deposition height, while the changes are systematically managed through the scan sequence, balancing complexity with benefit.
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 effectively prevents the formation of large stepped parts, resulting in a smoother surface and higher-quality three-dimensional objects with reduced visual impact from contour-like patterns, especially for surface-colored objects.
Implementation Method 1
inkjet heads for forming three-dimensional objects (formed articles) using forming apparatuses (3D printers) (inkjet forming method). Such apparatuses with inkjet heads employ inkjet lamination technique to form three-dimensional objects, in which inks discharged from inkjet heads are deposited to form multiple ink layers.
Data Source
AI summary
A forming apparatus for forming a three-dimensional object is provided. The forming apparatus includes: a data storage, storing multiple pieces of slice data; a discharge head, discharging a forming material; a forming platform; a main scan driver, i.e., a first direction scan driver, driving the discharge head to perform a main scan as a first direction scan; and a material-accumulating direction driver, changing a head-platform distance between the discharge head and the forming platform. The main scan driver, based on a respective one of the multiple pieces of slice data, drives the discharge head to perform a plurality of the main scans at the same position in the three-dimensional object currently formed.