Thermal Substrate Inkjet Detection for Clear Ink Contrast
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Solution Overview
Problem
In three-dimensional printing, detecting inoperative inkjets is challenging due to the low contrast between clear inks/materials and substrates, leading to difficulties in analyzing test patterns and resulting in malformation of printed objects, which are only identified after completion, causing inefficiencies and scrapped products.
Innovation Solution
An apparatus with a thermal substrate, optical sensor, actuator, and controller that ejects test dots onto a thermal substrate to identify inoperative inkjets by analyzing changes in optical density, allowing for real-time detection and restoration during printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If clear ink or clear material is used for printing, then the aesthetic quality and transparency of the printed object is improved, but the detectability of the printed pattern by imaging systems deteriorates due to low contrast
Solution Approach 1:
A thermal substrate is introduced as an intermediary between the clear ink/material and the imaging system. The substrate contains a thermal indicator that changes optical properties (color, reflectivity, or absorption) in response to thermal energy from the deposited material, thereby converting the invisible clear material deposition into a detectable optical signal without altering the final transparent object
2Productivity
If detection of inoperative inkjets is performed using traditional imaging systems with clear materials, then the printing process continues uninterrupted, but the ability to identify and correct inoperative inkjets deteriorates due to insufficient contrast in test patterns
Solution Approach 1:
The thermal substrate utilizes color changes (or optical property changes) in response to thermal energy from deposited material. When clear ink or material is deposited on the substrate, the thermal energy causes the substrate's optical indicator to change color or optical properties, providing high-contrast visual feedback that enables accurate detection of inkjet operability while maintaining printing continuity
3Speed
If printing operations are completed without real-time detection, then the printing process is simpler and faster, but the quality control and product yield deteriorate due to undetected inoperative inkjets
Solution Approach 1:
The thermal substrate performs preliminary detection of material deposition and inkjet functionality during the printing process itself, before the printing operation is completed. By providing real-time optical feedback on material deposition quality, the system enables immediate identification of inoperative inkjets, allowing for corrective action before defective objects are produced, thus maintaining both speed and quality
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
Enables real-time detection and restoration of inoperative inkjets, improving product yield and printing efficiency by identifying and addressing issues before completion, ensuring proper object formation.
Implementation Method 1
a supply of thermal substrate... to enable the predetermined number of material drops to form a test dot for each inkjet on the thermal substrate... and to identify inoperative inkjets in the printhead with reference to the data received from the optical sensor that corresponds to optical densities of the thermal substrate
Implementation Method 2
an optical sensor configured to generate electrical signals data corresponding to an area of material drops on the substrate... to identify inoperative inkjets in the printhead with reference to the data received from the optical sensor that corresponds to optical densities of the thermal substrate
Data Source
AI summary
An apparatus detects inoperative inkjets during printing. The apparatus operates the printhead or printheads in the printer to form test pattern on a thermal substrate. The heat of the materials used to form the test pattern increase the optical density of the areas where the materials land. The area where the test pattern is formed is imaged and the image data are analyzed to identify inoperative inkjets.