3D Shaping Control for Uniform Layers With Less Clear Ink
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Solution Overview
Problem
Conventional 3D printing methods waste ink and degrade the surface quality of shaped objects due to non-uniform layer thickness, necessitating excessive use of clear ink to achieve uniformity, which is then scraped off and discarded.
Innovation Solution
A shaping device and method that utilize a color ink ejection position determining means and a clear ink ejection position determining means to precisely control the ejection of transparent ink based on slice images, ensuring uniform layer thickness by adjusting dot sizes and presence/absence of ink ejection at each position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If clear ink is ejected to all positions to ensure uniform layer thickness, then layer thickness uniformity is improved, but ink waste increases
Solution Approach 1:
The patent applies local quality by determining clear ink ejection necessity individually for each ejection position based on color ink ejection patterns. The clear ink ejection position determining means analyzes slice images to identify positions where clear ink is actually needed to achieve uniform layer thickness, rather than uniformly ejecting clear ink to all positions. This localized approach ensures layer thickness uniformity while minimizing unnecessary clear ink consumption and waste.
2Manufacturing precision
If excessive clear ink is used to achieve uniform layer thickness, then layer thickness uniformity is improved, but surface quality degrades
Solution Approach 1:
The patent determines clear ink ejection necessity locally for each ejection position based on actual color ink ejection patterns and slice image analysis. By precisely identifying positions where clear ink is needed to compensate for color ink volume variations, the system achieves layer thickness uniformity without excessive clear ink application. This prevents surface quality degradation that would result from over-application of clear ink.
Solution Approach 2:
The patent performs preliminary analysis of slice images and color ink ejection patterns before clear ink ejection to predict positions requiring clear ink supplementation. The clear ink ejection position determining means uses this preliminary information to strategically eject clear ink only where needed, achieving uniform layer thickness while maintaining surface quality by avoiding unnecessary clear ink application that would cause degradation.
3Manufacturing precision
If clear ink is scraped off to remove excess layer thickness, then layer thickness uniformity is improved, but ink waste increases and surface quality degrades
Solution Approach 1:
The patent performs preliminary determination of clear ink ejection positions using slice image analysis and color ink ejection pattern recognition before the actual ejection process. By predicting positions where clear ink is needed to achieve target layer thickness, the system ejects the precise amount of clear ink required, eliminating the need for subsequent scraping operations. This preliminary action prevents both ink waste and surface quality degradation that would result from scraping.
Solution Approach 2:
The patent implements a feedback mechanism where the clear ink ejection position determining means uses slice image data and color ink ejection information to dynamically determine clear ink ejection positions and amounts. This feedback-based approach ensures that clear ink is ejected only where and in the amount needed to achieve uniform layer thickness, eliminating the need for scraping operations that would waste ink and degrade surface quality.
Data Source
AI summary
A method of shaping a solid object based on a digital model by forming and layering a plurality of separate layers of the solid object is provided. The method includes obtaining, from the digital model, data corresponding to a plurality of slice images indicating cross-sectional shapes and color arrangements of respective separate layers; dividing the slice image of each separate layer into a plurality of divided slice images by each color represented by each of inks of a plurality of colors; determining an ejection timing of each of the inks of the plurality of color and a clear ink, for forming each separate layer by using the data; and forming the separate layer by causing a color ink head and a clear ink head to eject each of the inks of the plurality of colors and the clear ink at the respective determined ejection timings.