Color-and-Clear Ink 3D Shaping for Uniform Layer Thickness
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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 and excessive use of clear ink for flattening.
Innovation Solution
A shaping device and method that determines the ejection of color and clear inks based on slice images, using quantization processes to optimize ink layer thickness by adjusting dot sizes and ejection positions, reducing the need for excessive clear ink and minimizing surface degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a larger and constant amount of clear ink is ejected to ensure uniform layer thickness, then the layering thickness uniformity is improved, but the ink waste increases and surface quality degrades
Solution Approach 1:
The patent applies local quality by determining clear ink ejection positions based on the actual color ink ejection pattern. Instead of uniformly ejecting clear ink across the entire layer, the system selectively ejects clear ink only at positions where color ink is ejected or adjacent to color ink regions. This localized approach ensures layer thickness uniformity is achieved precisely where needed while minimizing unnecessary clear ink consumption and associated waste.
Solution Approach 2:
The patent implements preliminary action by determining the clear ink ejection positions in advance based on the slice image data and color ink ejection pattern before actual printing. The control unit analyzes the color ink ejection positions from the quantization process and pre-calculates where clear ink should be ejected to achieve uniform layer thickness, thereby optimizing ink usage and preventing waste before the printing process begins.
2Manufacturing precision
If a larger and constant amount of clear ink is ejected to ensure uniform layer thickness, then the layering thickness uniformity is improved, but the surface quality of the shaped object degrades
Solution Approach 1:
The patent applies local quality by restricting clear ink ejection to specific local regions rather than uniformly across the entire surface. Clear ink is ejected only at positions where color ink is present or in immediate proximity to color ink regions. This localized strategy achieves the necessary layer thickness uniformity in critical areas while avoiding excessive clear ink accumulation that would otherwise degrade the overall surface quality of the shaped object.
Solution Approach 2:
The patent implements preliminary action by pre-determining clear ink ejection positions based on the slice image analysis and color ink ejection pattern before printing commences. The control unit calculates optimal clear ink placement in advance, ensuring that clear ink is applied only where it contributes to layer thickness uniformity without causing surface quality degradation from excessive or misplaced clear ink ejection.
3Manufacturing precision
If clear ink is ejected to all ejection positions to ensure uniform layer thickness, then the layering thickness uniformity is improved, but the clear ink usage increases
Solution Approach 1:
The patent applies local quality by selectively ejecting clear ink only at specific ejection positions where color ink is present or adjacent to color ink regions, rather than uniformly ejecting clear ink to all ejection positions. This targeted approach maintains layer thickness uniformity in areas where it is necessary while significantly reducing clear ink consumption in areas where color ink already provides sufficient material.
Solution Approach 2:
The patent implements preliminary action by determining clear ink ejection positions in advance based on the slice image data and color ink ejection pattern. The control unit analyzes which ejection positions require clear ink supplementation to achieve uniform layer thickness and pre-calculates the optimal clear ink ejection locations, thereby minimizing clear ink usage while ensuring layer thickness uniformity where required.
Data Source
AI summary
A shaping device shaping an object by forming and layering each layer based on slice images indicating cross-sectional shapes and color arrangements of the object include: a color ink ejection position determining means determining presence/absence of ejection of each ink of colors for coloring to each ejection position constituting the layer based on the slice image corresponding to the layer; a clear ink ejection position determining means determining necessity of ejection of a clear ink to each ejection position based on presence/absence of ejection of ink of each color for coloring to each ejection position determined in the color ink ejection position determining means; and a layer forming means causing a color ink head and the clear ink head to eject ink of each color and the clear ink to each ejection position as determined by the color ink ejection position and clear ink ejection position determining means.