Strobe Light Drop Characterization for 3D Printing Precision
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Solution Overview
Problem
Current 3D printing technologies, particularly magnetohydrodynamic (MHD) printers, face challenges with non-uniform jetting of liquid metal drops, leading to inferior quality objects due to manual and error-prone detection of drop jitter.
Innovation Solution
A method and system that uses a synchronized light source to illuminate and capture images of drops, enabling detection and characterization of drop size and location, with image processing techniques like Canny edge detection and binary masking to adjust printer parameters for improved drop uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual detection of drop jitter is used, then device complexity is reduced, but manufacturing precision deteriorates due to error-prone manual measurement
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system using high-speed camera and strobe light to capture and analyze drop jetting, eliminating human error and providing precise measurement of drop size and position
Solution Approach 2:
The patent introduces an intermediary detection system consisting of high-speed camera, strobe light, and image processing software that acts as a mediator between the drop jetting process and the control system, enabling automated feedback for precision control
2Manufacturing precision
If automated detection system is implemented, then manufacturing precision is improved through accurate drop characterization, but device complexity increases due to additional components
Solution Approach 1:
The system performs self-characterization by using the high-speed camera to automatically capture, process, and analyze drop images, with the computer system independently calculating drop size and position metrics without requiring external manual measurement tools
Solution Approach 2:
The patent employs periodic strobe light pulses synchronized with the drop jetting frequency to illuminate and capture individual drops at regular intervals, enabling consistent and repeatable measurements throughout the printing process
3Measurement precision
If high-speed camera with strobe light is used, then measurement precision is improved for drop characterization, but use of energy increases due to lighting and imaging requirements
Solution Approach 1:
The strobe light operates in periodic pulses rather than continuous illumination, synchronized with the drop jetting frequency, which dramatically reduces energy consumption while providing sufficient illumination for high-speed capture of each individual drop
Solution Approach 2:
The high-speed camera continuously captures images at high frame rates, ensuring that no drops are missed and providing continuous data stream for real-time monitoring and control, maximizing the utility of the energy invested in imaging
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
Automated detection and characterization of drops reduce drop jitter, enhancing the quality of 3D printed objects by allowing real-time adjustments to printing parameters, improving consistency and efficiency.
Implementation Method 1
A 3D printer builds (e.g., prints) a 3D object from a computer-aided design (CAD) model, usually by successively depositing material layer upon layer... capturing a video of liquid metal drops being jetted through a nozzle of the 3D printer while a strobe light illuminates the drops
Implementation Method 2
illuminating the drops with a light source as the drops descend from the nozzle. The light source emits first and second pulses of light at a second frequency. The first pulse of light illuminates the first drop. The second pulse of light illuminates the second drop
Implementation Method 3
capturing a first image of the first drop and a second image of the second drop as the first and second drops descend from the nozzle
Implementation Method 4
an electrical current flows through a metal coil, which produces time-varying magnetic fields that induce eddy currents within a reservoir of liquid metal compositions
Implementation Method 5
Coupling between magnetic and electric fields within the liquid metal results in Lorentz forces that cause drops of the liquid metal to be ejected (also referred to as jetted) through a nozzle of the printer
Data Source
AI summary
A method includes illuminating a drop with a pulse of light from a light source. A duration of the pulse of light is from about 0.0001 seconds to about 0.1 seconds. The method also includes capturing an image, video, or both of the drop. The method also includes detecting the drop in the image, the video, or both. The method also includes characterizing the drop after the drop is detected. Characterizing the drop includes determining a size of the drop, a location of the drop, or both in the image, the video, or both.