3D Printer Perimeter Infill With Quantization Error Distribution
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Solution Overview
Problem
Three-dimensional (3D) object printers that eject discrete material drops face issues with local anomalies and incorrect part height due to inconsistent drop spacing, leading to deformities and structural instability, especially when forming perimeters in parts with small number of drops per perimeter.
Innovation Solution
A method and system for a 3D object printer that distributes quantization errors across layers by modifying machine-ready instructions to adjust the number and placement of material drops, using a controller to identify and correct drop spacing errors, and employing a blue noise generator to decorrelate phase variations, ensuring accurate material distribution and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete material drops are used to form perimeters in 3D printed parts, then the manufacturing process becomes suitable for drop-on-demand printing, but local anomalies and incorrect part height occur due to inconsistent drop spacing
Solution Approach 1:
The system dynamically adjusts drop spacing parameters based on the specific perimeter geometry and layer requirements. By modifying the drop spacing parameter adaptively rather than using a fixed value, the system maintains material consistency across varying perimeter lengths and configurations, resolving the height accuracy issue while preserving drop-on-demand capabilities
Solution Approach 2:
The system implements feedback mechanisms to monitor and correct drop placement accuracy in real-time. By tracking actual drop positions and comparing them against target positions, the system can identify and compensate for spacing inconsistencies, preventing cumulative errors in part height and maintaining manufacturing precision
2Ease of manufacture
If discrete material drops are ejected to form perimeters, then the printing process enables additive manufacturing with melted metal or thermoplastic, but local part deformity occurs due to drop spacing errors
Solution Approach 1:
The system performs preliminary calculations and planning for drop placement before actual printing begins. By pre-determining optimal drop positions and spacing for each perimeter based on geometric analysis, the system prevents local deformity from occurring in the first place, ensuring structural integrity is maintained throughout the additive manufacturing process
Solution Approach 2:
The system adaptively modifies drop spacing parameters based on perimeter-specific requirements. By changing the spacing parameter dynamically rather than applying a uniform value, the system ensures consistent material distribution across all perimeters, preventing local anomalies that would compromise part reliability
3Productivity
If the number of drops per perimeter is reduced to print smaller features, then the printing time decreases, but quantization errors become more significant and cause noticeable defects
Solution Approach 1:
The system dynamically adjusts drop spacing parameters based on the specific perimeter length and geometric requirements. By optimizing the spacing parameter for each perimeter rather than using a fixed value, the system achieves smoother perimeters even with fewer drops, maintaining manufacturing precision while preserving productivity benefits
Solution Approach 2:
The system implements dynamic drop spacing that adapts to perimeter length and complexity. Rather than using static spacing values, the system varies the spacing dynamically based on real-time geometric analysis, ensuring consistent perimeter quality across different feature sizes and reducing quantization error visibility
4Ease of operation
If standard drop spacing is used for all perimeters, then the printing process is simplified, but incorrect material quantity results in wrong part height
Solution Approach 1:
The system automatically adjusts drop spacing parameters based on perimeter-specific requirements without requiring manual intervention. By changing the spacing parameter adaptively for each perimeter, the system maintains correct material quantity and part height consistency while preserving ease of operation through automated parameter management
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 solution effectively distributes quantization errors across layers, making them imperceptible and ensuring that the accumulated error is never more than one quantization unit, thereby maintaining part integrity and preventing error accumulation, which enhances the structural stability of printed parts.
Implementation Method 1
An electrical current is passed through the conductor to produce an electromagnetic field that causes the meniscus of the melted metal at a nozzle of the chamber to separate from the melted metal within the chamber and be propelled from the nozzle
Data Source
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AI summary
A slicer in a material drop ejecting three-dimensional (3D) object printer determines the number of material drops to eject to form a perimeter in an object layer and distributes a quantization error over the layers forming the perimeter. The slicer also identifies the location for the first material drop ejected to form the perimeter using a blue noise generator.