3D Printer Drop Volume Compensation via Raster Data Modification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Three-dimensional printers face issues with consistent functionality due to volumetric variations in inkjet drop volumes, leading to surface variations and potential scrapping of objects, which is time-consuming and costly.
Innovation Solution
A printer system that includes a platen, printhead, optical sensor, and controller to detect and compensate for volumetric drop variations by generating and modifying raster image data to ensure uniform material distribution across layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three-dimensional printing is used without compensation mechanisms, then the printing process is simple and fast, but surface variations occur due to inkjet drop volume inconsistencies leading to object scrapping
Solution Approach 1:
The system performs preliminary characterization of each inkjet's drop volume before actual printing. Drop volume measurements are taken and stored in a lookup table, allowing the controller to compensate for variations by adjusting raster image data based on pre-measured characteristics. This preliminary action eliminates surface variations without adding complexity to the printing process itself.
Solution Approach 2:
The system implements feedback by measuring actual drop volumes ejected by each inkjet and using this information to adjust subsequent printing operations. The controller modifies raster image data based on measured drop volume variations, creating a closed-loop system that automatically compensates for inkjet inconsistencies and maintains surface uniformity.
2Productivity
If inkjet drop volume variations are not compensated, then the printing process is fast and simple, but significant surface variations accumulate over multiple layers requiring object scrapping
Solution Approach 1:
The system pre-characterizes each inkjet's drop volume and stores this information in a lookup table before printing begins. During printing, the controller simply retrieves pre-calculated compensation values from the lookup table based on the inkjet's position and measured characteristics, allowing fast compensation without slowing down the printing process.
Solution Approach 2:
The system changes the parameters of the raster image data based on measured drop volume variations. By modifying the digital model parameters for each inkjet according to its characteristics, the system compensates for volume differences and maintains consistent column heights across all inkjets throughout the printing process.
3Reliability
If compensation for drop volume variations is implemented, then surface uniformity is maintained and scrapping is reduced, but the system complexity and measurement requirements increase
Solution Approach 1:
The system uses feedback from optical sensors that measure drop volume or column height to automatically adjust printing parameters. The controller receives measurement data and modifies raster image data accordingly, creating a self-correcting system that maintains object quality consistency without requiring complex manual intervention or sophisticated control algorithms.
Solution Approach 2:
The system changes physical or operational parameters such as drop ejection timing, frequency, or volume based on sensor feedback. By dynamically adjusting these parameters during printing, the system compensates for variations in inkjet performance and maintains reliable object quality without adding significant system complexity.
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
The system effectively compensates for drop volume variations, maintaining object quality and reducing the need for scrapping, thereby saving time and resources.
Implementation Method 1
an optical sensor configured to generate data corresponding to a topography and measurement of the material on the platen
Data Source
AI summary
A printer compensates for variations in ejected material drop volumes occurring during production of the layers for the formation of an object in a three-dimensional printer. The printer includes an optical sensor that generates topographical and measurement data of each layer of the object after each layer is printed. Differences in height between columns of material being formed by the ejectors in the printhead are identified with reference to the data produced by the sensor and raster data used to operate the printhead are modified adjust the formation of a next layer in the object.