3D Printing Pass Pixel Height Variation
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Solution Overview
Problem
Existing methods for printing 3D and relief objects with varying heights suffer from visible contouring artifacts due to different curing behaviors and material effects, particularly on smoothly sloped surfaces, when using pass pixels of varying heights, which hinders high surface quality and printing speed.
Innovation Solution
A method that selects pass pixel heights from a set of at least two positive heights based on random data to vary the composition and frequency of pass pixel heights, ensuring that the nominal pixel height is maintained without adding noise to the geometry, allowing for accelerated printing while reducing contouring artifacts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pass pixels of varying heights are used to accelerate printing, then printing speed is improved, but visible contouring artifacts appear on smoothly sloped surfaces
Solution Approach 1:
The patent applies local quality by varying pass pixel heights selectively based on the local geometry of the object surface. Pass pixels are assigned different heights from a set of available heights depending on the local slope and curvature characteristics, allowing the printing process to adapt to local surface requirements rather than using a uniform height approach throughout the entire print area.
Solution Approach 2:
The patent implements preliminary action by pre-calculating and assigning optimal pass pixel heights from a set of available heights before the actual printing process. The system analyzes the 3D model data in advance, determines the appropriate height for each pass pixel based on the local geometry, and creates a height assignment map that guides the printing process, thereby preventing contouring artifacts before they occur.
2Manufacturing precision
If pass pixel heights are varied to maintain nominal pixel height, then Z-resolution is improved, but the complexity of selecting appropriate heights increases
Solution Approach 1:
The patent applies parameter changes by utilizing a discrete set of predefined pass pixel heights rather than allowing continuous height variation. This quantization of height parameters simplifies the selection process while still providing sufficient resolution to maintain accurate Z-dimensional representation of the printed object, balancing precision with computational and operational simplicity.
3Manufacturing precision
If random selection of pass pixel heights is used, then contouring patterns are broken, but the predictability of the printing process decreases
Solution Approach 1:
The patent implements preliminary action by pre-determining the random selection sequence of pass pixel heights before printing begins. The system generates a predetermined pattern of height assignments that incorporates randomness to break contouring patterns while maintaining overall statistical consistency, ensuring that the printing process remains predictable and controllable despite the random element.
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 reduces visible contouring artifacts by breaking the spatial contouring pattern of iso-elevated positions, enabling faster printing with improved visual quality and Z-resolution, even when using pass pixels of different heights, by varying the droplet volume in ink jet printing.
Implementation Method 1
a print system, in particular an ink jet print system, for printing an object on a support
Implementation Method 2
For example, radiation curable ink, in particular UV curable ink, may be used
Data Source
AI summary
A printing system and method of printing an object having a surface of varying height, by a printer configured to print a number of pass images on top of each other in a number of passes, including: deriving from an object image a number of pass images to be printed on top of each other, including: establishing pass pixels of the pass images for which pass pixels a pass pixel height is defined, where a sum of the defined heights of a sequence of pass pixels that corresponds to a respective pixel of the object image equals the height of that pixel of the object image; and printing the pass images on top of each other. An amount of printed material that is printed per printed pass pixel is varied in accordance with the defined pass pixel heights. The pass pixels heights are selected, based on random data, from a respective set of at least two positive pass pixel heights.