FFF Printer X/Y Dynamics from Centerline and Line-Width Analysis
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Solution Overview
Problem
Existing methods for compensating nozzle offset in 3D printing require multiple compensation parameters without sufficient knowledge of printer performance, leading to inefficiencies and potential irrelevance.
Innovation Solution
A method involving depositing a pattern of lines on a support using an FFF printer, imaging the pattern, and analyzing geometric features to determine properties such as orthogonality, scaling errors, and hysteresis, which can be done with low-end imaging devices by compensating for their errors using an imaging error map.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple compensation parameters are used for nozzle offset compensation, then the compensation coverage is improved, but the complexity of parameter selection and determination increases
Solution Approach 1:
The patent applies preliminary action by pre-calculating and storing multiple compensation parameters in a lookup table before actual printing operations. The system determines nozzle offset compensation parameters in advance based on predetermined compensation values, eliminating the need for complex real-time parameter selection during printing. This resolves the contradiction by maintaining comprehensive compensation coverage while simplifying the operational process.
2Measurement precision
If high-end imaging devices are used for pattern analysis, then the measurement precision is improved, but the cost and complexity of the system increases
Solution Approach 1:
The patent applies the copying principle by creating a digital scan copy of the printed pattern and performing all analysis operations on this copy rather than requiring direct high-precision optical measurement. The scan data is processed to determine geometric features (line widths, distances, angles) and calculate printer properties. This approach achieves sufficient measurement precision for calibration purposes while avoiding the cost and complexity of high-end imaging equipment.
3Ease of manufacture
If a simple line pattern is deposited for analysis, then the ease of manufacture is improved, but the amount of information obtained about printer properties is reduced
Solution Approach 1:
The patent applies dimensionality change by analyzing a simple 1D line pattern across multiple dimensions of printer performance. By varying the orientation, position, and configuration of lines in the pattern, the system extracts information about X/Y scaling, orthogonality, nozzle offset, and dynamic properties from what appears to be a simple geometric feature. This resolves the contradiction by maintaining pattern simplicity while maximizing the information content through multi-dimensional analysis.
Data Source
AI summary
A method of determining one or more printer properties of an FFF printer, comprising the steps of: a) depositing a pattern (1) of one or more lines on a support (2) using the FFF printer; b) making an image of the deposited pattern (1) on the support (2) using an imaging device; c) analysing one or more geometric features of the pattern (1) in the image; and d) determining the one or more printer properties of the FFF printer based the one or more geometric features.