3D Optical Component Printing Nozzle Deviation Compensation
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Solution Overview
Problem
Existing three-dimensional optical component printing technologies face inaccuracies and non-uniformities due to deviations in ejection rates between nozzles, leading to optical defects like diffractive phenomena, as malfunctioning nozzles are not identified in real-time and their locations change over time due to clogging.
Innovation Solution
A method that identifies malfunctioning nozzles by measuring surface properties and adjusting ejection rates and nozzle operations in real-time, ensuring proper functioning nozzles maintain consistent ink deposition, and compensating for inaccuracies by adjusting the amount and number of droplets from malfunctioning nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If continuous printing with multiple layers is performed, then productivity is improved, but manufacturing precision deteriorates due to cumulative nozzle deviations
Solution Approach 1:
The system performs preliminary characterization of each nozzle's ejection properties before production printing. By measuring and storing reference values for each nozzle in advance, the system prepares compensation data beforehand, allowing high-speed production printing without real-time measurement delays while maintaining precision through pre-calculated compensation.
Solution Approach 2:
The system implements feedback by continuously monitoring printed layer properties and comparing them against reference values. When deviations are detected, the system automatically adjusts subsequent printing parameters or identifies malfunctioning nozzles, creating a closed-loop control system that maintains precision across multiple layers while preserving productivity.
2Manufacturing precision
If real-time measurement and compensation is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system performs self-characterization and self-diagnosis by automatically measuring its own nozzle ejection properties and identifying malfunctioning nozzles without external intervention. This self-service capability reduces the need for complex external calibration equipment and simplifies the overall system architecture while maintaining high precision.
Solution Approach 2:
The system manages complexity by focusing measurements and compensation on critical parameters only - specifically nozzle ejection volume and positioning accuracy. By concentrating on these key parameters rather than attempting to control all possible variables, the system achieves high precision with manageable device complexity.
3Ease of operation
If malfunctioning nozzles are not identified, then ease of operation is maintained, but manufacturing precision deteriorates due to cumulative errors
Solution Approach 1:
The system automatically identifies malfunctioning nozzles through self-diagnosis routines without requiring operator intervention. The system characterizes each nozzle's performance, detects deviations from reference values, and flags problematic nozzles automatically, maintaining ease of operation while preventing precision degradation.
Solution Approach 2:
The system implements automated feedback monitoring that continuously tracks nozzle performance and alerts operators to malfunctioning nozzles. This feedback mechanism maintains operational simplicity by handling the complex detection and diagnosis tasks automatically, while ensuring precision is maintained through timely identification and compensation of nozzle issues.
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 significantly enhances printing accuracy, preventing optical defects and ensuring high-quality three-dimensional optical components like lenses by maintaining consistent ejection characteristics and compensating for nozzle deviations.
Implementation Method 1
a measuring unit for contactless measuring physical parameters of the at least one deposited droplet, wherein the physical parameter can be a geometrical parameter, like thickness and/or surface contour of a layer of deposited droplets
Implementation Method 2
it is well known to cure the imprinted material by using light irradiation for reducing the overall printing time
Data Source
Figure 1~2
AI summary
A method and a corresponding printing system (1) for printing a three-dimensional structure (2), in particular an optical component, by depositing droplets (6) of printing ink side by side and one above the other in several consecutive depositing steps (10) by means of a print head (3), wherein in each depositing step (10) a plurality of droplets (6) is ejected simultaneously by a plurality of ejection nozzles (4) of the print head (3), wherein after at least one depositing step (10) surface properties of a pre-structure (2') built up by the deposited droplets (6) are measured by a measuring unit (16) in a measuring step (13) and wherein ejection characteristics of the ejection nozzles (4) are determined in dependency of the measured surface properties in a determining step (14) and at least one following depositing step (10) is performed in dependency of the determined ejection characteristics.