Inline Failure Detection for 3D Printer Curing Light Sources
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Solution Overview
Problem
In 3D object printers using UV curable inks, malfunctioning or insufficient curing light sources can lead to incomplete curing of inks, resulting in the emission of volatile organic compounds (VOCs) and potential removal of uncured ink, posing environmental and user concerns.
Innovation Solution
An inline failure detection system that includes a two-dimensional array of printheads, a curing light source, a heat-resistant member holding thermal paper, and a controller to detect light intensity issues by analyzing color changes in the thermal paper exposed to the curing light source, allowing for real-time correction of light emitting diodes (LEDs).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the curing light source is used to cure UV ink, then the ink is cured and bonded to the article, but if the light source malfunctions or emits insufficient light, the ink does not completely cure leading to VOC emissions and ink removal
Solution Approach 1:
The patent applies preliminary action by implementing an inline failure detection system that tests the curing light source before it is needed for production printing. The IFD system continuously monitors light output and detects failures proactively, allowing the system to alert operators and schedule maintenance before actual curing failures occur that would lead to VOC emissions and ink removal.
Solution Approach 2:
The patent implements feedback through the inline failure detection system that continuously monitors the curing light source performance and provides real-time information about light output status. This feedback loop enables the system to detect when light intensity falls below threshold levels and trigger alerts or shutdowns, preventing incomplete curing and associated harmful effects.
2Use of energy by moving object
If the curing light source emits insufficient light, then energy consumption is reduced, but the UV ink does not completely cure resulting in environmental and user concerns
Solution Approach 1:
The inline failure detection system provides continuous feedback on light output intensity, allowing the system to monitor whether the curing light source is operating within the optimal range required for complete ink curing. This ensures that energy consumption is optimized while maintaining reliable curing performance and preventing incomplete curing scenarios.
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 complete curing of UV inks, reduces VOC emissions, and allows for timely correction of light source failures, maintaining print quality and environmental safety.
Implementation Method 1
analyzing color changes in the thermal paper exposed to the curing light source
Implementation Method 2
applying energy to the thermal paper
Implementation Method 3
a UV light source is used to cure the ink. The UV light source may be used to initiate a photochemical reaction that generates a crosslinked network of polymers
Data Source
AI summary
A print system and a method for detecting inline failure of a curing light source of a 3D object printer are disclosed. For example, the print system includes a plurality of printheads, a curing light source, an inline failure detection (IFD) system, a movable member to hold an object, a heat resistant member coupled to the movable member that holds a thermal paper for testing operation of the curing light source and a controller to control movement of the movable member to move the object past the array of printheads, to operate the plurality of printheads to eject the marking material onto the object as the object passes the two-dimensional array of printheads, to operate the curing light source to apply energy to the thermal paper and to cure the marking material, and to operate the IFD system to read the thermal paper to detect a failure of the curing light source.