3D Printing Nozzle Row Allocation for Droplet Failure Compensation
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Solution Overview
Problem
Existing three-dimensional object production methods, such as inkjet methods, face issues with droplet ejection failures or missing nozzles, leading to groove formation in unit layers during multi-pass printing, especially when the head moves in the main scanning direction.
Innovation Solution
A method where one pass constitutes one pixel group, with pixels formed at predetermined intervals, dispersing them in the main scanning direction to prevent groove formation, and incorporating droplet ejection control and nozzle adjustment to compensate for failed nozzles, ensuring unit layers are formed satisfactorily despite ejection failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-pass printing is performed with the head moving in the main scanning direction, then droplet ejection coverage is improved, but groove formation occurs in unit layers due to sequential alignment of pixels from failed nozzles
Solution Approach 1:
The patent changes the arrangement pattern of pixels in the main scanning direction from sequential to dispersed. By forming pixels at predetermined intervals in one pass and using multiple passes to complete the unit layer, pixels from the same nozzle are dispersed rather than aligned sequentially, preventing groove formation while maintaining complete droplet ejection coverage.
2Productivity
If the head scans at high speed to reduce shaping time, then productivity is improved, but droplet ejection precision deteriorates due to reduced time for proper droplet placement
Solution Approach 1:
The patent divides the unit layer formation into multiple passes, with each pass forming pixels at predetermined intervals. This segmentation allows the head to scan at high speed for each individual pass while ensuring proper droplet ejection precision, as the system can maintain accurate droplet placement for the dispersed pixel pattern without requiring excessive scanning time.
3Device complexity
If conventional multi-pass printing aligns pixels sequentially in the main scanning direction, then simple control is maintained, but groove formation occurs reducing manufacturing precision
Solution Approach 1:
The patent introduces dynamic control where the head performs multiple passes with different scanning patterns. The control system dynamically adjusts which pixels are formed in each pass based on predetermined intervals, transforming the static sequential arrangement into a dynamic dispersed arrangement that prevents groove formation while maintaining manageable control complexity.
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 successful formation of unit layers even with droplet ejection failures or missing nozzles, reducing shaping time and maintaining scan speed, while preventing groove formation in the main scanning direction.
Implementation Method 1
a head for ejecting droplets; the ejection controller causes the droplets to be ejected from a part of the nozzles
Implementation Method 2
a method that laminates layers produced by ejecting a modeling material that cures by receiving light irradiation
Data Source
Figure 1
Figure 2
Figure 3A~3C
AI summary
To form unit layers of a three-dimensional object satisfactorily despite occurrence of droplet ejection failure and the like. A three-dimensional object production method according to the present invention includes a step of allocating different regions of a nozzle row (22) to different pixel groups (25A, 25B) that are obtained by dividing the pixel rows constituting a unit layer (25) into n groups (where n is an integer ≥2), and a step of forming the pixel rows by nozzles (21) included in each region forming one pixel group (25A, 25B).