Interleaved Nozzle Scanning for Smoother 3D Printed Layers
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Solution Overview
Problem
Existing three-dimensional printing technologies face challenges in reducing waviness and achieving smooth, uniform layer formation, particularly in additive manufacturing processes like 3D inkjet printing.
Innovation Solution
The method involves activating interleaved subsets of nozzle arrays for adjacent scan patterns, using different building materials, and forming interleaved scan patterns with controlled dispensing and hardening without leveling, to create an opaque interior bulk region surrounded by a color-textured outer region, with non-random dilution patterns to reduce waviness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional continuous scan patterns are used for dispensing building material, then material deposition is efficient, but waviness occurs in the printed layers
Solution Approach 1:
The nozzle array is divided into multiple subsets, with each subset responsible for dispensing building material at specific locations. This segmentation allows selective activation of subsets to create interleaved scan patterns, reducing waviness by preventing standing wave formation while maintaining efficient material deposition through coordinated subset operation.
Solution Approach 2:
The method employs periodic activation of different nozzle subsets in an interleaved scan pattern sequence. By systematically activating subsets in a periodic manner rather than continuously, the system prevents standing wave formation that causes waviness, while maintaining high productivity through optimized subset coordination.
2Productivity
If all nozzles are activated simultaneously for rapid printing, then productivity increases, but standing waves cause waviness in the printed layers
Solution Approach 1:
The nozzle array is segmented into multiple subsets that are activated in an interleaved sequence rather than simultaneously. This segmentation maintains high productivity by keeping many nozzles active while preventing standing wave formation through spatial and temporal distribution of activation, thereby achieving both speed and uniformity.
Solution Approach 2:
The system dynamically activates and deactivates different nozzle subsets based on the scan pattern requirements. This dynamic control allows the system to adapt activation patterns to prevent standing waves while maintaining high overall nozzle utilization, achieving both productivity and layer uniformity.
3Strength
If material is dispensed in dense continuous layers, then structural integrity is improved, but waviness reduces surface quality
Solution Approach 1:
The material deposition is segmented into interleaved scan patterns from different nozzle subsets. This segmentation creates a deposition pattern that maintains sufficient material density for structural integrity while preventing the continuous layer formation that causes waviness, thereby improving surface texture.
Solution Approach 2:
Different nozzle subsets are activated in specific locations and sequences to create local variations in deposition patterns. This local quality approach ensures adequate material density for strength in critical areas while preventing waviness in surface regions through optimized subset activation patterns.
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
This approach effectively reduces waviness and enhances the smoothness of printed objects by controlling material distribution and hardening, resulting in improved surface texture and structural integrity.
Implementation Method 1
a timing parameter for application of electrical pulses to a piezoelectric nozzle of an inkjet printing head is controlled so as to dispense droplets of a material from the nozzle
Implementation Method 2
Depending on the building material, the layers may then be cured or solidified using a suitable device
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A method of printing a three-dimensional object, comprises: for each of a plurality of arrays (122) of nozzles, activating a subset of nozzles of the array to dispense a respective building material from the subset, so as to form an interleaved scan pattern (508) of dispensed materials. The method comprises hardening the interleaved scan pattern, and repeating the activating and the hardening to form a stack of hardened interleaved scan patterns.