3D Metal Drop Ejection Control for Real-Time Geometry Compensation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Three-dimensional (3D) metal object printers face issues with drop size and spacing variations during the printing process, leading to height and geometry errors, which can result in asymmetric features and require halting the manufacturing process or scrapping the part.
Innovation Solution
A method and system that use an optical sensor to generate image data of the printed object, compare it to the original design data, and modify machine-ready instructions to compensate for displacement errors in real-time, adjusting drop spacing and tool paths to maintain intended dimensions and shape without halting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time optical sensing and instruction modification are implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system implements real-time feedback by capturing images of the printed object during manufacturing, comparing actual layer heights to target values, and using this information to dynamically modify subsequent printing instructions. This closed-loop feedback mechanism continuously corrects drop size variations to maintain manufacturing precision.
Solution Approach 2:
The patent replaces mechanical measurement systems with optical sensing technology. Instead of using physical probes or contact-based measurement devices, the system uses optical sensors to capture images and measure layer heights, thereby improving precision without adding mechanical complexity.
2Productivity
If continuous printing with real-time compensation is used, then productivity is improved, but measurement precision requirements increase
Solution Approach 1:
The system performs preliminary measurements of layer heights during the printing process itself, before completing the entire build. This allows compensation to be applied to subsequent layers while maintaining continuous printing operations, rather than measuring after the fact.
Solution Approach 2:
Real-time optical feedback enables the system to detect and compensate for drop size variations during printing. The feedback loop processes images, calculates height deviations, and adjusts printing parameters on-the-fly, maintaining both productivity and measurement accuracy.
3Manufacturing precision
If drop spacing is adjusted to compensate for height errors, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system dynamically adjusts drop spacing based on real-time measurements of layer heights. Rather than using fixed spacing, the control system modifies spacing parameters layer-by-layer to compensate for accumulated height errors, maintaining geometric accuracy through adaptive control.
Solution Approach 2:
The patent changes printing parameters (drop spacing, ejection frequency) in response to measured deviations. By dynamically modifying these parameters based on actual layer heights, the system corrects geometric errors without requiring complex hardware modifications.
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 allows for continuous printing by compensating for drop size and spacing errors, ensuring accurate geometry and preventing the need for part scrapping, by integrating the corrected drop spacing into subsequent layers and adjusting tool paths as necessary.
Implementation Method 1
an optical sensor configured to generate image data of a metal object being formed by the 3D metal object manufacturing system
Implementation Method 2
An electrical current is passed through the conductor to produce an electromagnetic field that causes the meniscus of the liquid metal at a nozzle of the chamber to separate from the liquid metal within the chamber and be propelled from the nozzle
Data Source
AI summary
A method operates a three-dimensional (3D) metal object manufacturing system to compensate for displacement errors that occur during object formation. In the method, image data of a metal object being formed by the 3D metal object manufacturing system is generated prior to completion of the metal object and compared to original 3D object design data of the object to identify one or more displacement errors. For the displacement errors outside a predetermined difference range, the method modifies machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement errors and operates the 3D metal object manufacturing system using the modified machine-ready instructions.