Rotating Stage Discharging Head Nozzle Density for Uniform Dot
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Solution Overview
Problem
Existing methods for fabricating solid freeform objects using material jetting face challenges in achieving uniform dot density across the stage, leading to non-uniform objects due to varying peripheral speeds and dot density differences between the inner and outer regions, which are exacerbated by the need for increased nozzle frequency or ink discharge on the outer side to compensate.
Innovation Solution
A device with a rotating stage and variable distances between the discharging and exposing devices, featuring a discharging head with more nozzles along the shorter direction from the center to the periphery, ensures uniform dot density by adjusting the number of nozzles and ink distribution to match the varying peripheral speeds, thereby minimizing the difference in dot density between the inner and outer regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of nozzles is increased along the shorter direction from the center toward the periphery, then uniform dot density is achieved across the stage, but device complexity increases
Solution Approach 1:
The discharging head is designed with non-uniform nozzle distribution where the number of nozzles along the shorter direction increases from the center toward the periphery of the stage. This local variation in nozzle density compensates for the higher peripheral speed at outer regions, achieving uniform dot density across the entire stage while addressing the specific problem of non-uniform material distribution
Solution Approach 2:
The discharging head employs an asymmetric nozzle arrangement where nozzle frequency varies spatially. The shorter direction of the discharging head is perpendicular to the radial direction, and the nozzle count along this shorter direction increases radially outward, creating an asymmetric pattern that matches the rotational velocity profile of the stage
2Adaptability or versatility
If the distance between the stage and discharging device is made variable, then fabrication flexibility is improved, but device complexity increases
Solution Approach 1:
The distance between the stage and discharging device is made variable rather than fixed, allowing dynamic adjustment during operation. This enables the system to adapt to different fabrication requirements, object sizes, and material types, significantly improving fabrication flexibility and versatility
3Productivity
If the peripheral speed varies from inner to outer region, then rotation efficiency is improved, but dot density uniformity deteriorates
Solution Approach 1:
The discharging head incorporates spatially varying nozzle density where the number of nozzles along the shorter direction increases from the center toward the periphery. This local adaptation compensates for the higher peripheral speed at outer regions, ensuring that material is deposited at appropriate intervals across the entire stage despite the rotational speed variation
Solution Approach 2:
The system changes the nozzle frequency parameter radially across the stage. By increasing the number of nozzles along the shorter direction from center to periphery, the system adjusts the material discharge rate to match the varying peripheral speed, maintaining consistent dot density throughout the fabrication area
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 configuration allows for the fabrication of uniform solid freeform objects by reducing waste and energy consumption, enhancing productivity and accuracy, and enabling faster fabrication while maintaining a compact device size.
Implementation Method 1
a discharging device disposed over the stage and including a discharging head having one or more nozzles, the discharging head for discharging a curing composition to the stage
Implementation Method 2
an exposing device disposed over the stage that exposes the stage to active energy
Data Source
AI summary
A device for fabricating a solid freeform object includes a stage that rotates, a discharging device disposed over the stage and includes a discharging head each having one or more nozzles, the discharging head for discharging a curing composition to the stage and an exposing device disposed over the stage that exposes the stage to active energy, wherein the distance between the stage and the discharging device is variable and the distance between the stage and the exposing device is variable, wherein the shorter direction of the discharging head is perpendicular to the direction from the center of rotation of the stage toward the peripheral of the stage, wherein the number of the nozzles along the shorter direction increases in the direction from the center of rotation of the stage toward the peripheral of the stage.