3D Printer Inkjet Detection via Conductive Substrate
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Solution Overview
Problem
Three-dimensional printers face inefficiencies due to inoperative inkjets, which are not detectable until the printing process is complete, leading to malformation of objects and reduced product yield.
Innovation Solution
An apparatus with an electrically conductive substrate, sensors, and actuators that detect inoperative inkjets by generating electrical signals and moving components to identify faulty inkjets during the printing process, allowing for real-time restoration and continued production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing continues without detection of inoperative inkjets, then productivity is maintained, but manufacturing precision deteriorates due to malformation of printed objects
Solution Approach 1:
The system performs preliminary detection of inoperative inkjets by printing test patterns before production printing. The controller detects which inkjets are non-functional by analyzing the test pattern output, and selectively activates only functional inkjets for subsequent production printing, preventing malformation before it occurs.
Solution Approach 2:
The system extracts and isolates the detection function from the printing process by using a separate test pattern printing and analysis mechanism. This allows the system to identify and exclude inoperative inkjets without interrupting the main production printing workflow, maintaining productivity while ensuring quality.
2Manufacturing precision
If real-time detection of inoperative inkjets is implemented, then manufacturing precision is improved, but device complexity increases due to additional sensors and actuators
Solution Approach 1:
The test pattern serves multiple functions: it acts as both a diagnostic tool for detecting inoperative inkjets and as a reference pattern for comparison during production printing. The same printheads used for production printing are also used to create test patterns, eliminating the need for separate detection hardware and reducing overall system complexity.
Solution Approach 2:
The system uses its own printing capability to perform self-diagnosis. The controller directs the printheads to print test patterns and then analyzes the output to detect inoperative inkjets, allowing the printing system to monitor and diagnose its own functionality without external detection equipment.
3Manufacturing precision
If test printing is performed before production printing, then manufacturing precision is improved, but loss of time increases due to additional printing steps
Solution Approach 1:
The system performs a minimal test pattern printing operation that covers only the essential functionality check, rather than completing a full production print job. The test pattern uses a subset of inkjets and a simplified pattern design, requiring less time and material while still effectively identifying inoperative inkjets.
Solution Approach 2:
The test pattern printing is performed as a preliminary step that quickly identifies inoperative inkjets before production printing begins. By detecting and excluding faulty inkjets in advance, the system prevents time loss from producing defective objects that would require rework or scrapping.
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
Enables the detection and restoration of inoperative inkjets during printing, improving product yield and efficiency by preventing malformation and allowing continuous production.
Implementation Method 1
an electrical current sensor operatively connected to the electrically conductive member, the electrical current sensor being configured to generate an electrical signal in response to electrical current being detected in the electrically conductive member
Implementation Method 2
a second actuator operatively connected to the electrically conductive member, the actuator being configured to move the electrically conductive member towards the electrically conductive substrate
Data Source
AI summary
A printer detects inoperative inkjets during printing of three dimensional objects. The printer includes an electrically conductive substrate onto which a printhead ejects building material in a test pattern. A plurality of electrically conductive members arranged in a pattern corresponding to the test pattern are moved a predetermined distance towards the substrate so ends of the members either contact the surface of the substrate or the building material on the substrate. An electrical current source coupled to the substrate produces a current in those members contacting the substrate. Thus, the inkjets corresponding to the members in which an electrical current is produced are identified as inoperative and the printing of an object can be suspended to take remedial action with regard to the printhead.