3D Printer Ejector Compensation via Waveform Adjustment
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Solution Overview
Problem
Three-dimensional printers face inefficiencies due to inoperative ejectors, which can lead to malformed objects and significant waste, as malfunctioning ejectors can only be detected after completing long print jobs, requiring scrapping and re-printing.
Innovation Solution
A method and system that detect malfunctioning ejectors and modify firing signals for functional ejectors to increase drop volume, allowing for continuous production of properly formed objects by compensating for the malfunctioning ejector during the printing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional three-dimensional printing is used without real-time ejector detection, then the printing process can complete without interruptions, but the quality of the printed object cannot be assessed until the printing operation is completed, resulting in scrapped objects and lost time
Solution Approach 1:
The system performs preliminary detection of ejector functionality during the printing process by monitoring droplet formation and deposition in real-time. This allows identification of malfunctioning ejectors before they can compromise the entire print job, enabling corrective actions to be taken during printing rather than after completion.
Solution Approach 2:
The system implements continuous feedback monitoring by sensors that detect droplet ejection quality and position. This real-time feedback loop allows the control system to identify malfunctioning ejectors and adjust printing parameters or compensate for defects during the printing process, maintaining object quality consistency without requiring completion of the entire print job.
2Reliability
If ejectors are monitored continuously during printing, then real-time detection of malfunctioning ejectors is achieved, but the complexity of the printing system increases due to additional sensors and control mechanisms
Solution Approach 1:
The system uses the existing printing process and material deposition itself as the monitoring mechanism. By analyzing the droplets being printed - their formation, size, and deposition patterns - the system detects ejector malfunctions without requiring separate dedicated sensors for each ejector. The printing process monitors itself through the quality of its own output.
Solution Approach 2:
The control system performs multiple functions: it controls the printing process, monitors droplet ejection quality, detects malfunctioning ejectors, and implements compensation strategies. This multi-functionality reduces the need for separate dedicated monitoring hardware, as the existing control infrastructure is leveraged to perform detection and compensation tasks.
3Device complexity
If malfunctioning ejectors are detected after printing is completed, then the printing process remains simple, but significant time and resources are wasted due to scrapped objects and need to repeat print jobs
Solution Approach 1:
The system detects ejector malfunctions during the printing process itself, before the object is completed and before time is wasted on defective prints. By performing detection in advance during printing, the system can stop or correct the process early, preventing the time loss associated with completing and scrapping defective objects.
Solution Approach 2:
Real-time feedback during printing allows immediate detection and response to ejector failures. This prevents the accumulation of time loss that would occur if detection happened after completion, as corrections can be made during the printing process itself, reducing or eliminating the need to repeat entire print jobs.
4Productivity
If functional ejectors increase drop volume to compensate for malfunctioning ejectors, then continuous production of properly formed objects is enabled, but the precision of individual drop placement must be maintained while adjusting volumes
Solution Approach 1:
The system applies different drop volumes selectively to different ejectors based on their operational status. Functional ejectors that need compensation receive adjusted (increased) drop volumes, while malfunctioning ejectors are identified and excluded from normal operation. This localized adjustment maintains overall precision while enabling continuous production.
Solution Approach 2:
The control system dynamically changes the firing signal parameters of functional ejectors to adjust drop volume. By modifying electrical parameters (voltage, pulse width) of the ejectors, the system compensates for missing droplets from malfunctioning ejectors, maintaining the required manufacturing precision through calculated parameter adjustments rather than physical modifications.
Data Source
AI summary
A method for compensating for inoperative ejectors in a three-dimensional object printer has been developed. A printer detects an inoperative ejector in a printhead. The printer identifies functional ejectors that print at locations adjacent to locations where the inoperative ejector fails to print a drop. The printer modifies firing signals for the functional ejectors so those ejectors print drops having an increased drop volume at the locations adjacent to locations where the inoperative ejector fails to print a drop. The printer prints a first layer of material drops using the modified firing signals. The printer advances the printhead in the cross-process direction between layers so that locations where the inoperative ejector fails do print a drop do not coincide between layers.