Print Data Modification at Printhead Die Overlap Areas
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Solution Overview
Problem
Printing systems with overlapping printhead dies suffer from artefacts at the boundaries between adjacent printhead dies, resulting in concave shapes on the trailing and leading edges of printed objects due to aerodynamic turbulences.
Innovation Solution
A method that modifies print data by shifting and masking it to compensate for drop placement errors caused by aerodynamic turbulences, adding additional drops in advance to fill gaps at the overlap areas between printhead dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If printhead dies are arranged with overlap areas to enable continuous printing, then printing productivity is improved, but artefacts appear at the boundaries between adjacent printhead dies
Solution Approach 1:
The patent applies preliminary action by modifying print data in advance to account for expected drop placement errors. Additional drops are added at overlap areas before printing occurs, and these compensatory drops are printed ahead of time to fill gaps that would otherwise appear at printhead die boundaries. This pre-compensation approach resolves the boundary precision issue while maintaining the overlapping printhead configuration for high productivity.
2Area of stationary object
If printhead dies overlap each other to cover the entire print bed, then printing area is improved, but aerodynamic turbulences cause drop placement errors
Solution Approach 1:
The patent applies local quality by implementing position-dependent compensation strategies. Different drop placement corrections are applied at different locations on the print bed, with specific compensation parameters used for overlap areas versus non-overlap areas. This allows the system to maintain high printing area coverage while addressing drop placement precision issues locally at problematic boundary regions through targeted print data modifications.
3Manufacturing precision
If additional drops are printed to compensate for gaps at overlap areas, then surface quality is improved, but print data complexity increases
Solution Approach 1:
The patent applies self-service by implementing automated print data modification that generates compensatory drop patterns through systematic rules. The system automatically identifies overlap areas, calculates required compensation based on predetermined parameters, and generates modified print data without manual intervention. This automation manages the increased complexity through algorithmic processing rather than manual data preparation, maintaining surface quality while reducing operational burden.
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 effectively reduces or minimizes artefacts on printed objects by compensating for drop placement errors, improving the printing process yield and surface quality.
Implementation Method 1
aerodynamic turbulences caused by a movement of the printhead arrangement which may result in concave artefacts at trailing and/or leading edges
Data Source
AI summary
A method for reducing artefacts in printed objects comprises receiving print data to be printed by a printhead arrangement, the printhead arrangement being movable in a print direction and comprising a plurality of printhead dies, wherein printhead dies adjacent to each other comprise an overlap area when viewed in the print direction. The print data to be printed are modified near and/or at the overlap areas between printhead dies of the printhead arrangement to compensate for drop placement.