Optical Sensor Array for 3D Printer Color Fidelity
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Solution Overview
Problem
Three-dimensional object printers face issues with color fidelity and uniformity during the printing process, leading to faded or inaccurately colored objects, especially when transitioning between different colors, resulting in scrapped products and reduced productivity.
Innovation Solution
A printer equipped with an optical sensor array that includes a light source and photo detectors, which generates data on the object's surface color, allowing the controller to adjust the material ejection and movement of printheads to maintain color accuracy and uniformity by compensating for color discrepancies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If inkjets eject colored material during printing, then color is produced in the object surface, but inkjet deterioration causes faded colors or incorrect hues
Solution Approach 1:
The optical sensor array performs preliminary detection of color fidelity during the printing process, allowing the system to identify inkjet deficiencies before they result in completely defective objects. This enables early intervention through compensatory procedures.
Solution Approach 2:
The system implements continuous feedback by monitoring color output with the optical sensor array and using this information to adjust printing parameters in real-time. This feedback loop compensates for inkjet deterioration and maintains color fidelity throughout the printing process.
2Adaptability or versatility
If color transitions occur between embedded objects, then multi-color objects are created, but color non-uniformity occurs at boundaries
Solution Approach 1:
The optical sensor array provides localized color monitoring at specific regions including boundaries between embedded objects. This enables region-specific detection and compensation of color non-uniformity, allowing different printing parameters to be applied to different areas of the object.
Solution Approach 2:
The system changes printing parameters such as inkjet ejection timing, material composition, or layer thickness in response to detected color non-uniformity at boundaries. These parameter adjustments compensate for color transitions and maintain uniformity between different colored regions.
3Manufacturing precision
If continuous monitoring is implemented, then color fidelity is maintained, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical color adjustment mechanisms with an optical sensing and computational control system. The optical sensor array combined with digital signal processing and controller algorithms provides continuous color monitoring and compensation without requiring complex mechanical interventions during printing.
4Measurement precision
If color defects are detected after printing, then accurate detection is achieved, but productivity decreases due to scrapping and reprinting
Solution Approach 1:
The optical sensor array performs preliminary color fidelity detection during the printing process rather than after completion. This allows the system to identify and correct color defects while printing is still in progress, preventing the need to scrap and reprint entire objects.
Solution Approach 2:
The monitoring and compensation operations continue throughout the printing process without interrupting production. The optical sensor array and controller operate concurrently with the printing process, maintaining continuous color fidelity assurance while keeping the printer productive.
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
The system ensures color fidelity and uniformity throughout the printing process, reducing the need for scrapping objects and increasing printer productivity by real-time monitoring and adjustment of color output.
Implementation Method 1
an optical sensor array configured to generate data corresponding to light reflected by an upper surface of the object on the substrate
Implementation Method 2
an optical sensor array having a light source and a plurality of photo detectors
Data Source
AI summary
A three-dimensional object printer generates image data of an object being formed in the printer with an optical sensor array and identifies the color of an upper surface of the object. The controller compares the identified color to a predetermined range about an expected color for the upper surface and operates ejectors to eject material of a color different than the identified color in response to the identified color being outside of the predetermined range.