Print Medium Thickness Calibration for Thermal Deformation
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Solution Overview
Problem
In 2D and 3D printing, the heating of print media can cause thermal deformation, leading to changes in its thickness, which affects the alignment accuracy of print heads and results in dot placement errors due to altered distances between the print head and the media.
Innovation Solution
A method involving the measurement of the initial and final thickness of the print medium after heating, with the calculation of an offset value to adjust the print head's position, ensuring accurate alignment and minimizing dot placement errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the print medium is heated to dry, cure or bind the print material, then the print material is properly processed on the print medium, but the print medium undergoes thermal deformation causing thickness change and dot placement errors
Solution Approach 1:
The patent measures the thickness of the print medium before heating and calculates a compensation value in advance. This preliminary measurement and calculation allow the system to pre-determine the expected thermal deformation, which is then used to adjust print head positioning or printing parameters before the actual heating process occurs, thereby compensating for the anticipated thickness change and maintaining dot placement accuracy
Solution Approach 2:
The patent dynamically adjusts printing parameters based on the measured thickness and calculated compensation values. By changing parameters such as print head Z-position, focal distance, or even print resolution in response to the predicted thermal deformation, the system maintains accurate dot placement despite the print medium's thickness changes during heating
2Manufacturing precision
If the print head position is adjusted to compensate for thickness change, then dot placement accuracy is improved, but the system complexity increases due to additional measurements and calculations
Solution Approach 1:
The patent replaces complex mechanical adjustment mechanisms with computational methods. Instead of using sophisticated mechanical systems to physically track and compensate for thickness changes in real-time, the system uses thickness measurements taken before heating, calculates compensation values through algorithms, and applies these as offsets to print head positioning or printing parameters, achieving the same effect with simpler hardware
Solution Approach 2:
The patent creates a digital model or representation of the thickness change through measurement and calculation. By capturing the thickness data before heating and using it to generate compensation values, the system creates a computational copy of the thermal deformation behavior, which is then used to adjust printing parameters without requiring direct real-time physical intervention during the heating process
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 allows for precise calibration of the print head's distance to the print medium, reducing dot placement errors and improving image quality by accounting for thermal deformation of the print medium.
Implementation Method 1
the heating of print media can cause thermal deformation, leading to changes in its thickness
Data Source
AI summary
An example method to determine the change of a print medium due to heat dilatation or contraction is described. In that example the thickness before and after heating is determined and an offset value may be calculated to calibrate a print head to print medium distance.