UV Ink Leveling Layer for Banding Reduction in 3D Printing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming uneven portions using inkjet printers often result in banding, which appears as horizontal grooves due to nozzle clogging or paper feeding variations, affecting the appearance and impression of the final three-dimensional object.
Innovation Solution
An information processing apparatus generates data for forming layers of UV-curable ink, acquiring data on the depth of grooves and adjusting the number of lamination times or ink recording amount based on the elapsed time from discharge to curing, to form a leveling layer that reduces banding by extending the curing time beyond that of the original uneven portion formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ink drops are discharged from a plurality of recording heads to form an uneven portion, then the uneven portion can be formed on the recording medium, but banding appears as horizontal grooves in the moving direction of the recording head
Solution Approach 1:
The patent applies preliminary action by forming a leveling layer before the final uneven portion formation. The leveling layer is created first to fill grooves and smooth the surface, then the uneven portion is formed on top. This preliminary smoothing action prevents banding from appearing in the final product while maintaining the desired three-dimensional shape characteristics.
Solution Approach 2:
The patent segments the ink discharge process into two distinct stages: first discharging ink to form a leveling layer for surface smoothing, then discharging ink to form the uneven portion. This segmentation allows each stage to optimize for its specific function - the leveling layer for eliminating banding and the uneven portion for creating the desired shape - thereby resolving the contradiction between ease of manufacture and manufacturing precision.
2Manufacturing precision
If the number of lamination times or ink recording amount is increased to reduce banding, then surface smoothness improves, but ink consumption increases
Solution Approach 1:
The patent applies local quality by making the ink discharge amount position-dependent. The control unit determines the ink discharge amount based on the dot clock signal, creating different ink amounts in different spatial locations. This allows the leveling layer to receive sufficient ink for smoothing while the uneven portion receives optimized ink amounts, thereby reducing overall ink consumption compared to uniform high-amount discharge.
Solution Approach 2:
The patent uses partial action by applying ink discharge selectively - the leveling layer receives ink discharge to achieve smoothing, but the subsequent uneven portion formation uses controlled, partial ink discharge only where needed for shape creation. This avoids excessive ink discharge across the entire surface, optimizing the balance between surface smoothness and ink consumption.
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
The solution effectively reduces banding by forming a leveling layer that smooths the surface, minimizing the perception of grooves and optimizing ink consumption, while maintaining the desired shape characteristics of the uneven portion.
Implementation Method 1
generates data for forming a layer of ink to be cured by being irradiated with an ultraviolet ray, on an uneven portion
Data Source
AI summary
An information processing apparatus generates data for forming a layer of ink to be cured by being irradiated with an ultraviolet ray, on an uneven portion formed on a recording medium using ink to be cured by being irradiated with an ultraviolet ray, and the information processing apparatus includes an acquisition unit configured to acquire first data that has information corresponding to a depth of a groove to be generated on a surface of the uneven portion in a case where the uneven portion is formed on the recording medium, and a generation unit configured to generate second data that represents a number of lamination times of ink or a recording amount of ink for forming the layer of ink, based on the first data.