3D Printing Head Tilting for Concave Corner Access

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Solution Overview

Problem

Existing three-dimensional object printing apparatuses using ink jet methods struggle to print on concave corners of objects due to the ink jet head interfering with the surface, as the discharge direction is orthogonal and cannot be adjusted effectively.

Innovation Solution

A three-dimensional object printing apparatus with a liquid discharge head and a moving mechanism that changes its position and pose relative to the workpiece, allowing the discharge vector to have a component towards the concave surface, enabling printing on surfaces with corners by tilting the nozzle array and adjusting the scanning axis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the ink jet head maintains a discharge direction orthogonal to the surface, then printing quality on flat surfaces is improved, but printing on concave corners becomes impossible due to head interference

Engineering Contradiction:

Improveprinting qualityVSAvoidprinting capability on concave corners

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the discharge direction of the ink jet head variable rather than fixed. The control unit adjusts the discharge direction dynamically based on the surface geometry, allowing the head to print on both flat surfaces and concave corners by changing its orientation angle according to the local surface normal vector.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent changes the discharge direction parameter of the ink jet head based on the surface characteristics. By calculating the angle between the discharge direction and the surface normal vector, the system adjusts the discharge direction parameter to maintain optimal printing conditions on varying surface geometries, resolving the contradiction between flat surface quality and corner accessibility.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If the ink jet head is moved closer to print on concave corners, then printing capability is improved, but the head contacts the workpiece surface causing interference

Engineering Contradiction:

Improveprinting capability on concave cornersVSAvoidhead interference with surface

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The system dynamically adjusts the discharge direction angle based on the concavity of the surface. By calculating the angle between the discharge direction and the surface normal vector, the control unit modifies the head orientation to print on concave corners without moving the head closer, thus avoiding contact and interference with the workpiece surface.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

Instead of moving the ink jet head in the vertical dimension (closer to the surface) to print on concave corners, the patent rotates the head in the angular dimension. This dimensional change allows the discharge direction to align with the surface normal vector on concave areas, achieving corner printing while maintaining a safe distance from the workpiece.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Ease of operation

If the discharge direction is constantly orthogonal to the surface, then simplicity of control is maintained, but printing on complex geometries becomes impossible

Engineering Contradiction:

Improvecontrol simplicityVSAvoidprinting capability on complex geometries

Core Design Contradiction:

Ease of operationVSAdaptability or versatility

Solution Approach 1:

The system uses feedback from the surface geometry information to automatically adjust the discharge direction. The control unit receives data about the workpiece surface characteristics, calculates the appropriate discharge direction angle based on the surface normal vector, and adjusts the ink jet head orientation accordingly, maintaining ease of operation while enabling complex geometry printing.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs self-adjustment of the discharge direction based on pre-stored surface data. The control unit automatically calculates and applies the necessary angular adjustments without requiring manual intervention, maintaining operational simplicity while adapting to complex geometries through automated geometric compensation.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS12257774B2Three-dimensional object printing apparatus and three-dimensional object printing method

Publication Date: 2025.03.25 SEIKO EPSON CORP

AI summary

A three-dimensional object printing apparatus includes a liquid discharge head having a nozzle surface, a moving mechanism that changes a position and a pose of the liquid discharge head relative to a three-dimensional workpiece, and a controller. The workpiece has a first surface and a second surface that forms a corner bent or curved in a concave shape between the first surface and the second surface. When an axis along a scanning direction of the liquid discharge head with respect to the workpiece in a first printing operation of performing printing on the first surface is a first scanning axis and a normal vector of the nozzle surface in the first printing operation is a first discharge vector, the controller controls the driving of the moving mechanism such that the first discharge vector has a component in a direction toward the second surface along the first scanning axis.