Page-Width Inkjet Array for Rapid Prototyping Speed
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Solution Overview
Problem
Conventional rapid prototyping technologies using inkjet printing are limited by slow formation speed and labor-intensive quality checking, leading to inefficiencies in producing large-sized three-dimensional objects with high quality.
Innovation Solution
A rapid prototyping apparatus with a page-width array printing module, where multiple inkjet head structures are arranged in rows and moved synchronously along a single axis, enabling faster printing and automatic quality detection and compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional inkjet printing technology with single or few inkjet heads is used, then the printing quality can be maintained, but the printing speed is slow and formation time is long
Solution Approach 1:
The printing system is segmented into multiple independent inkjet head structures (first inkjet head structure, second inkjet head structure, etc.) arranged in parallel. Each inkjet head can independently print binding liquid, enabling simultaneous multi-point printing operations. This segmentation allows the system to maintain printing quality while dramatically increasing overall printing speed through parallel processing.
2Area of stationary object
If the inkjet head structure moves along multiple axes (X-axis and Y-axis) to cover the construction material, then the entire area can be printed, but the process is time-consuming and speed is limited
Solution Approach 1:
The system transitions from single-axis or two-axis sequential scanning to a multi-head parallel arrangement that effectively adds a spatial dimension to the printing process. Multiple inkjet heads are positioned at different locations along the construction material's length, allowing simultaneous printing across the entire area. This dimensional change eliminates the need for time-consuming multi-axis movement while maintaining full coverage.
3Ease of manufacture
If manual checking method is used to detect nozzle conditions, then the process is simple, but it is labor-intensive and subjective with reduced efficiency and accuracy
Solution Approach 1:
The manual mechanical checking process is replaced with an automated optical detection system. A detection module with light source and sensor automatically detects nozzle printing conditions by analyzing the printed patterns, eliminating the need for human operators to visually inspect. This substitution dramatically improves checking efficiency and accuracy while removing subjectivity from the evaluation process.
4Ease of operation
If conventional sequential printing process is used, then the system is simple to operate, but the formation of large-sized objects takes several hours
Solution Approach 1:
The system implements continuous parallel printing operations where multiple inkjet heads work simultaneously throughout the printing process. Unlike sequential printing where one head completes its task before the next begins, all inkjet heads continuously deposit binding liquid across different sections of the construction material at the same time. This continuity maintains operational simplicity while reducing total formation time from several hours to a fraction of that time.
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 speed and efficiency, reducing production time for large objects and improving quality by eliminating the need for labor-intensive manual checks and allowing real-time compensation for nozzle issues.
Implementation Method 1
printing high viscosity liquid binder on part of the powder by using the inkjet printing technology, so that the liquid binder and the powder stick together to become solidified
Data Source
AI summary
A rapid prototyping apparatus includes a construction platform, a movable platform, and a page-width array printing module. The construction platform includes a construction chamber. The movable platform and the construction platform are movable relative to each other. The page-width array printing module includes plural inkjet head structures. The printing platform and the movable platform are synchronously moved along a single direction in a reciprocating motion. The plural inkjet head structures are collaboratively defined as at least one page-width array printing unit. The plural inkjet head structures include respective inkjet chips. The inkjet chips are arranged in plural rows and in a staggered form, so that a printing width of the inkjet chips is larger than or equal to a width of a printed pattern. Moreover, at least one monochromatic print liquid is introduced into the construction chamber from the plural inkjet head structures.