3D Printing Nozzle Rows Prevent Ink Layer Errors

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Solution Overview

Problem

In three-dimensional object forming using inkjet heads, variations in nozzle discharge performance lead to unevenness in ink layer thickness, reducing the accuracy and quality of the formed object, especially when laminating layers with the same nozzle, which accumulates errors and affects forming speed and accuracy.

Innovation Solution

Employing multiple inkjet heads with nozzle rows that discharge ink droplets to different positions on each layer, ensuring that ink dots from the same nozzle are not stacked at the same position, and sharing nozzle rows for different ink types to optimize device efficiency and reduce costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the same nozzle is used to form multiple laminated ink layers, then the device complexity is reduced, but the manufacturing precision deteriorates due to accumulation of discharge performance variations

Engineering Contradiction:

Improvedevice complexityVSAvoidforming accuracy

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The patent divides the inkjet head into multiple nozzle rows (first nozzle row and second nozzle row) that are arranged in different directions. This segmentation allows different nozzles to form successive ink layers, preventing the accumulation of discharge performance variations while maintaining a relatively simple device structure without requiring complex mechanical repositioning mechanisms.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a new spatial dimension by arranging nozzle rows in different directions (first direction and second direction). This dimensional change allows the system to switch between different nozzles for successive layers without requiring mechanical movement in the traditional scanning direction, thereby improving precision while avoiding increased device complexity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Manufacturing precision

If mechanical control operations are performed to shift nozzle positions for each layer, then the manufacturing precision improves, but the productivity deteriorates due to increased time required for mechanical control

Engineering Contradiction:

Improveforming operation accuracyVSAvoidforming speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical repositioning system with a multi-directional nozzle row configuration. Instead of mechanically shifting the nozzle position for each layer, the system uses pre-positioned nozzle rows in different directions, allowing electronic switching between nozzles. This substitution eliminates time-consuming mechanical operations while maintaining high forming accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If multiple inkjet heads are used to form multiple ink layers, then the manufacturing precision improves by preventing error accumulation, but the device complexity increases

Engineering Contradiction:

Improveforming accuracyVSAvoiddevice complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges multiple nozzle rows into a single integrated inkjet head structure. The first and second nozzle rows are combined in one head unit, allowing the system to achieve the precision benefits of multiple heads while maintaining a simpler single-head configuration. This reduces device complexity while still preventing error accumulation through the use of different nozzles for successive layers.

Inventive Principle:

Principle #5Merging (Combining)

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 prevents the accumulation of discharge performance variations, enhances forming accuracy, reduces the risk of unevenness, and allows for faster and more precise three-dimensional object creation while minimizing device enlargement and cost.

Implementation Method 1

a nozzle for discharging ink droplets

Methodology Applied

Scientific EffectInkjet discharge:

Implementation Method 2

a solidifying agent for solidifying the liquid droplets

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS10293554B2Three-dimensional object forming device and three-dimensional object forming method

Publication Date: 2019.05.21 MIMAKI ENGINEERING CO LTD

AI summary

A three-dimensional object forming device, for forming a three-dimensional object by an additive manufacturing method, is provided. The three-dimensional object forming device includes: a head unit, having at least one inkjet head provided with at least one nozzle row; and a main scanning drive unit. The head unit has a plurality of nozzle rows, and forms a plurality of laminated ink layers on at least some area. Each of the nozzles in the plurality of nozzle rows discharges an ink droplet to each different position in an operation of forming one of the ink layers; and in an operation of forming at least any two ink layers, laminated successively, ink droplets are discharged in such a way that ink dots formed by the same nozzle are not stacked at the same position.