3D Printing Layer Formation Using Clear White Pigmented Material Distribution
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Solution Overview
Problem
3D object printing is time-consuming due to the need for multiple passes and struggles with accurate color reproduction on the surface of printed objects, especially when using pigmented materials, which often require thicker layers and can result in color variations and low resolution.
Innovation Solution
A 3D printing system that increases layer formation in a single pass by using multiple ejectors and a strategic combination of clear, white, and pigmented materials, where the proportion of materials changes with depth from the surface to achieve accurate color rendering and reduce manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple passes are used to print each layer, then color accuracy is improved, but manufacturing time increases significantly
Solution Approach 1:
The patent segments the printing process by separating structure formation (using clear and white materials) from color application (using pigmented materials). This allows different printheads to work simultaneously on different materials, enabling single-pass multi-material deposition that maintains color accuracy while reducing manufacturing time.
Solution Approach 2:
The patent introduces a new dimension by adding multiple printheads that can deposit different materials (clear, white, and pigmented) simultaneously in the same pass. This multi-dimensional approach to material deposition eliminates the need for sequential passes, resolving the time-accuracy tradeoff.
2Productivity
If the number of ejectors is increased to print multiple layers in a single pass, then productivity is improved, but system cost increases
Solution Approach 1:
The patent makes each printhead universal by enabling it to deposit multiple material types (clear, white, and pigmented materials) through a single ejector system. This multi-functionality allows single-pass multi-layer printing without increasing the number of printheads, thus maintaining productivity while controlling system cost.
Solution Approach 2:
The patent changes the material parameters by developing formulations that allow clear, white, and pigmented materials to be deposited from the same printhead system. This parameter change enables single ejectors to handle multiple materials, improving productivity without proportionally increasing device complexity.
3Manufacturing precision
If thick layers of pigmented material are used, then color saturation is improved, but image resolution deteriorates
Solution Approach 1:
The patent applies local quality by using white material as a base layer in specific regions where color accuracy is critical, then applying pigmented materials on top. This localized approach ensures high resolution in color-critical areas while maintaining sufficient pigment concentration for saturation where needed.
Solution Approach 2:
The patent creates composite material structures by layering white base material with pigmented overlay materials. This composite approach allows thin pigmented layers to achieve both high resolution (due to the smooth white base) and adequate saturation (through the pigment overlay), resolving the resolution-saturation tradeoff.
4Stability of the object's composition
If leveling is performed to remove material, then surface uniformity is improved, but color accuracy deteriorates
Solution Approach 1:
The patent performs preliminary action by depositing white base material and pigmented overlay material in the correct proportions during the printing process itself, rather than requiring post-printing leveling. This preliminary material distribution achieves surface uniformity while preserving color accuracy, eliminating the need for material removal.
Data Source
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AI summary
A three-dimensional object printer has a controller that operates pluralities of ejectors ejecting drops of different materials having different colors, at least one color of which is white, to produce objects with different levels of color saturation. The controller operates the pluralities of ejectors with reference to a function of a sum of an average number of drops per voxel in each layer, a target value of an average number of drops per voxel of colorants other than white in each layer, and a distance from a closest surface of the object for each material ejected by the ejectors. At a predetermined distance from a closest surface and greater, the controller operates the pluralities of ejectors to form voxels in layers of the object with only clear and white drops. At distances less than the predetermined distance, the number of clear drops increases and the number of white drops decreases.