3D Printing Coloring via Inner Layer Pre-Coloring
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Solution Overview
Problem
Inkjet additive manufacturing methods face challenges with incomplete coloring due to nozzle clogging and non-uniform ink discharge, leading to exposed underlayers and surface defects in three-dimensional objects.
Innovation Solution
An image processing device that receives three-dimensional object data and creates data for coloring both the outer layer and multiple inner layers of the object, ensuring adjacent coloring to prevent underlayer exposure and enhance surface quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coloring is applied only to the outer layer surface, then the manufacturing process is simple and fast, but nozzle clogging and non-uniform ink discharge cause incomplete coloring and exposed underlayers
Solution Approach 1:
The patent applies coloring to multiple inner layers in advance before the outer layer is fully formed. This preliminary action ensures that even if the outer layer has defective coloring due to nozzle issues, the inner layers provide complete coverage and prevent underlayer exposure.
Solution Approach 2:
The patent extends the coloring process from a two-dimensional surface application to a three-dimensional volumetric application by coloring multiple inner layers. This dimensional expansion ensures complete coverage throughout the object's depth, not just on the surface.
2Reliability
If coloring is applied to multiple inner layers, then surface quality is maintained even with defective discharges, but the processing time and complexity increase
Solution Approach 1:
By pre-coloring multiple inner layers before final outer layer formation, the system ensures that surface quality is guaranteed even if outer layer coloring fails. This preliminary action eliminates the need for rework and ensures reliable surface appearance.
Solution Approach 2:
The patent creates a cushion of colored inner layers that compensates for potential coloring defects in the outer layer. This beforehand cushioning ensures that even with non-uniform ink discharge or nozzle clogging, the surface quality remains stable and defects are hidden.
3Manufacturing precision
If the outer layer is colored to compensate for underlayer exposure, then surface defects are hidden, but ink consumption and processing complexity increase
Solution Approach 1:
Instead of applying excessive ink to the outer layer surface to cover defects, the patent distributes coloring through multiple inner layers in the third dimension. This volumetric approach achieves complete defect coverage with more efficient ink utilization.
Solution Approach 2:
The patent applies coloring selectively to specific inner layers that are adjacent to and support the outer layer, rather than uniformly coloring the entire object. This localized quality approach minimizes ink consumption while ensuring surface defects are properly covered.
Data Source
AI summary
An image processing device includes a data receiver to receive three-dimensional object data of an object and a circuitry to create three-dimensional data from the three-dimensional object data when coloring at least part of a surface of the object, to conduct the coloring to the outer layer of the surface and multiple inner layers of the object.