3D Printer Slicer for Constant-Velocity Sharp Corner Deposition
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Solution Overview
Problem
Existing 3D object printers experience errors in drop placement when forming features that require velocity changes in the relative motion of the ejector and platform, leading to irregularities and increased time in forming sharp corners.
Innovation Solution
A method and system where the ejector and platform move at a constant velocity to form features, using a slicer program to precisely place material drops by maintaining consistent relative movement along the edges of a feature, eliminating the need for deceleration and acceleration, thereby improving precision and reducing formation time for sharp corners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If velocity changes are implemented in the relative motion of the ejector and platform to form perimeter features, then the ability to form sharp corners is improved, but drop placement precision deteriorates due to acceleration and deceleration errors
Solution Approach 1:
Instead of changing velocity to form sharp corners (conventional approach), the patent inverts the approach by maintaining constant velocity and using a different mechanism (adjusted ejection timing and position) to achieve sharp corner formation without the harmful velocity changes that cause drop placement errors
2Manufacturing precision
If velocity changes are implemented to form perimeter features, then feature completeness is improved, but formation time increases due to deceleration and acceleration cycles
Solution Approach 1:
The patent maintains continuous motion at constant velocity between the ejector and platform, eliminating the stop-start cycles of deceleration and acceleration. This continuous action completes perimeter features while reducing formation time, as the system never loses momentum through velocity changes
3Manufacturing precision
If constant velocity is maintained in relative motion, then drop placement precision is improved, but the ability to form sharp corners deteriorates without velocity changes
Solution Approach 1:
The patent changes other parameters (ejection timing, drop placement position, layer geometry) to compensate for the constant velocity motion. By adjusting these parameters, sharp corners are formed through precise material deposition at constant velocity rather than through velocity changes, resolving the contradiction between precision and shape formation
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 allows for more precise placement of material drops and reduces the time required to form sharp corners, resulting in improved feature accuracy and efficiency compared to traditional 3D object printers.
Implementation Method 1
An electrical current is passed through the conductor to produce an electromagnetic field that causes the meniscus of the melted metal at a nozzle of the chamber to separate from the melted metal within the chamber and be propelled from the nozzle
Data Source
AI summary
A slicer in a material drop ejecting three-dimensional (3D) object printer generates machine ready instructions that operate components of a printer, such as actuators and an ejector having at least one nozzle, to form features of an object more precisely than previously known. The instructions generated by the slicer control the actuators to move the ejector and a platform on which the object is formed relative to one another at a constant velocity to form edges of the feature.