Drop-on-Demand Printing With Feedback-Controlled Drop Collisions
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Solution Overview
Problem
Existing drop on demand printing technologies face challenges in precisely controlling the coalescence of multiple drops in flight due to environmental factors and nozzle variability, leading to unintended collisions and deviations from planned trajectories.
Innovation Solution
A method and system for controlling drop collisions by measuring flight parameters using sensors, analyzing collision outcomes, and adjusting dispenser parameters in a feedback loop to ensure precise coalescence, utilizing cameras, lasers, and neural networks for real-time adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high precision nozzle control is used to enable drops to combine in flight, then drop coalescence can be achieved, but the system becomes sensitive to environmental factors such as temperature, humidity, and pressure variations
Solution Approach 1:
The system employs sensors (cameras, lasers, detectors) to measure actual drop collision outcomes and feeds this information back to the control system, which then adjusts nozzle parameters in real-time to compensate for environmental variations and maintain collision accuracy
Solution Approach 2:
The system dynamically adjusts dispensing parameters such as drop size, discharge timing, and nozzle positioning based on measured collision outcomes and environmental conditions, allowing the system to adapt to changing temperature, humidity, and pressure conditions
2Manufacturing precision
If multiple sensors and real-time adjustments are implemented to measure and control drop collisions, then collision precision is improved, but the device complexity increases
Solution Approach 1:
The control system integrates multiple functions into a single platform: sensors serve both measurement and control functions, the control system handles both real-time monitoring and parameter adjustment, reducing the need for separate dedicated components for each function
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
Ensures accurate and stable drop coalescence by maintaining desired collision outcomes, reducing satellite drops, and enhancing the precision of the printing process.
Implementation Method 1
The image can be captured by stroboscopic camera
Implementation Method 2
The collision can be measured by at least one laser and at least one detector configured to determine a change of intensity of light emitted by the lasers as the combined drop alters the path of light between the at least one laser and detector
Data Source
AI summary
A method of printing using drop-on-demand collision of multiple liquid drops, the method including: discharging a first liquid drop from a first dispenser and a second liquid drop from a second dispenser so that the first and second liquid drops coalesce in flight and form a combined drop; measuring, via at least one sensor, at least one flight parameter of the combined drop while the combined drop is in flight; comparing the measured flight parameter to a target criterion; and based on the comparison, automatically adjusting at least one discharge parameter for at least one of the first dispenser or the second dispenser before a subsequent discharge, wherein the method is performed in a printing apparatus configured to deposit the combined drop onto a substrate to form part of a printed structure.