3D Ink Jet Printing Raster Segmentation for Resolution and Productivity
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Solution Overview
Problem
3D ink jet printing faces a trade-off between high resolution and productivity, as high spatial resolution requires small nozzles and small ink droplets, limiting the frequency of droplet ejection and thus decreasing productivity.
Innovation Solution
Employing a coarse raster for jetting large droplets for high productivity and a finer raster for radiation-controlled curing to selectively form micro pixels, allowing for the reproduction of fine details while maintaining high productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high spatial resolution is pursued by using small nozzles and small ink droplets, then manufacturing precision is improved, but productivity deteriorates due to limited droplet ejection frequency
Solution Approach 1:
The patent divides the printing process into two distinct stages with different raster resolutions: a first printing stage using a first raster and a second printing stage using a second raster with higher spatial resolution. This segmentation allows each stage to be optimized independently - the first stage for productivity and the second stage for precision - thereby resolving the contradiction between manufacturing precision and productivity
Solution Approach 2:
The patent dynamically adjusts the raster resolution based on the printing stage and requirements. The system transitions from a coarser raster in the first printing to a finer raster in the second printing, allowing the process to adapt its resolution characteristics to the specific needs of each stage - building mass quickly initially, then refining details subsequently
2Productivity
If a coarse raster is used for jetting large droplets, then productivity is improved, but manufacturing precision deteriorates as fine details cannot be reproduced
Solution Approach 1:
The patent segments the printing process into two phases: first printing with a coarse raster for rapid material deposition and productivity, then second printing with a fine raster for precise detail reproduction. This segmentation allows the system to achieve both high productivity and fine detail capability by applying the appropriate raster resolution at the appropriate stage
Solution Approach 2:
The first printing with the coarse raster performs a preliminary action of depositing large droplets to quickly build up the bulk material and form macro pixels. This preliminary high-productivity step creates a foundation that is then refined by the second printing stage, which adds the fine detail structure needed for manufacturing precision
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 enables the creation of high-resolution three-dimensional objects with increased productivity by quickly forming macro pixels and selectively curing micro pixels, allowing for the removal of excess ink and precise detail reproduction.
Implementation Method 1
The curable liquid, which hereinafter will be designated as 'ink' for simplicity, may be of a type which is cured by being irradiated with a specific type of radiation, e.g. with UV light.
Implementation Method 2
A curing device for curing the ink with the resolution of the micro pixel raster may comprise a radiation source which emits a beam of radiation (e.g. UV light or an electron beam), and a controllable deflector which deflects the beam so as to direct it onto the micro pixels to be exposed.
Data Source
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AI summary
A method of 3D ink jet printing, the method comprising a step of jetting out droplets (20) of a curable liquid onto a substrate (12) in positions that fit into a predetermined raster (24); and a step of radiation-controlled curing of the liquid, wherein the radiation is applied at spots that also fit into a predetermined raster (26), characterized in that the raster (26) that is employed in the curing step has a higher resolution than the raster (24) employed in the jetting step.