Staggered Nozzle Rows for Even Ink Layers in 3D Printing
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Solution Overview
Problem
Conventional 3D printing devices using inkjet heads with nozzles aligned in the same line in the main scanning direction often result in uneven streaks and difficulties in forming smooth ink layers due to connected ink dots, especially when using ultraviolet curing ink.
Innovation Solution
The configuration of the 3D printing device includes nozzle rows with nozzles aligned in a direction intersecting the main scanning direction, allowing for overlapping positions in the perpendicular direction, preventing ink dots from connecting in the main scanning direction and enabling more even ink layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If nozzles of multiple ink jet heads are aligned in the same line in the main scanning direction, then the device complexity is reduced and ease of operation is improved, but ink dots connect in the main scanning direction causing uneven streaks and poor manufacturing precision
Solution Approach 1:
The patent transitions from one-dimensional linear alignment of nozzles to two-dimensional staggered arrangement. Multiple nozzle rows are positioned at different perpendicular offsets, creating a grid-like pattern that prevents ink dot connection in the main scanning direction while maintaining operational simplicity.
2Manufacturing precision
If nozzles of multiple ink jet heads are arranged in staggered positions in the perpendicular direction, then manufacturing precision is improved by preventing ink dot connection, but device complexity increases
Solution Approach 1:
The nozzle system is segmented into multiple independent nozzle rows, each positioned at a specific perpendicular offset. This segmentation allows each row to contribute to forming ink layers without interfering with adjacent rows, preventing ink dot connection while distributing the complexity across modular components.
3Ease of manufacture
If conventional ink jet head configuration is used for three-dimensional object formation, then ease of manufacture is improved, but uneven streaks are formed due to connected ink dots reducing manufacturing precision
Solution Approach 1:
The patent introduces asymmetric positioning of nozzle rows relative to each other in the perpendicular direction. Instead of symmetric alignment, each subsequent nozzle row is offset by a specific distance, creating an asymmetric staggered pattern that prevents ink dot connection while maintaining ease of manufacture through systematic positioning.
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 prevents uneven streaks and allows for faster, more accurate formation of three-dimensional objects by ensuring ink layers are flattened and formed with higher resolution and accuracy.
Implementation Method 1
a head unit including a plurality of nozzle rows that discharge ink droplets in an ink jet scheme
Implementation Method 2
Each of the plurality of nozzle rows discharges ink droplets of ultraviolet curing ink that cures by ultraviolet irradiation
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A three-dimensional object forming device (10), which forms a three-dimensional object (50) by an additive manufacturing method, is provided. The three-dimensional object forming device includes: a head unit (12), including a plurality of nozzle rows that discharge ink droplets in an ink jet scheme; and a main scanning drive unit (14) that causes the head unit to perform a main scanning operation, wherein each of the plurality of nozzle rows is a row along which the plurality of nozzles are aligned in a nozzle row direction that intersects the main scanning direction (Y), and the plurality of nozzle rows are arranged along the main scanning direction so that at least some of their positions in a perpendicular direction that intersects perpendicularly with the main scanning direction overlap each other, and in the perpendicular direction, respective positions of the nozzles in each nozzle row differ from respective positions of the nozzles in other nozzle rows. A three-dimensional object forming method is also disclosed.