System for adjusting operation of a printer during three-dimensional object printing to compensate for errors in object formation

• US 9,597,839 B2
• Filed: 06/16/2015
• Issued: 03/21/2017
• Est. Priority Date: 06/16/2015
• Status: Active Grant

• Current Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Original Assignee: Xerox Corporation (Xerox Holdings Corp.)
• Inventors: Lubin, Dara N., Buzzelli, John T., Dufort, Ron E., St. Martin, Kevin, Montfort, David B.
• Primary Examiner(s): Sultana, Nahida
• Application Number:
  US14/740,744
• Publication Number:
  US 20160368219A1
• Time in Patent Office: 644 Days
• Field of Search: 425/375, 425/174.4, 425/150, 264/40.1, 264/401, 264/308, 264/112
• US Class Current: 1/1
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/188 involving additional operations performed on the added layers, e.g. smoothing, grinding or thickness control surface shaping B29C59/00; after-treatment of articles without altering their shape B29C71/00
• CPC Class Codes: B29C 64/393 for controlling or regulating additive manufacturing processes
• CPC Class Codes: B29K 2105/0058 Liquid or visquous
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes

Abstract

A printer compensates for printing errors occurring during production of the layers for the formation of an object in a three-dimensional printer. The printer includes an optical sensor that generates data corresponding to edges of each layer of the object after each layer is printed. Differences between the raster data used to eject the material to form a layer and the data received from the optical sensor are used to modify the raster data that operates a printhead to form a next layer in the object.

Claims

1. A three-dimensional object printing system comprising:

a planar member;

at least one ejector configured to eject material towards the planar member to form an object on the planar member;

at least one interferometer that generates signals corresponding to distances between positions in a surface of the object being formed on the planar member, the interferometer being oriented differently than the ejector with reference to the object being formed on the planar member;

a material remover configured to remove material from the object being formed on the planar member; and

a controller operatively connected to the at least one interferometer, the ejector, and the material remover, the controller being configured to;

operate the at least one ejector to form the object on the planar member;

compare the distances between positions on the surface of the object being formed on the planar member that correspond to the signals received from the at least one interferometer to data corresponding to a plurality of views of the object being formed on the planar member;

identify a position on the object being formed on the planar member where material is to be removed or added to the object being formed on the planar member in response to the comparison of the distances and the data corresponding to the plurality of views exceeds a predetermined threshold; and

operate the material remover or the at least one ejector to remove or add material to the object being formed on the planar member at the identified position to modify positions on the surface of the object being formed on the planar member to positions identified in the data corresponding to the plurality of views.

2. The printer of claim 1, the controller being further configured to:

iteratively compare the distances to the data corresponding to the plurality of views, identify the position on the object, and operate the material remover or the at least one ejector until the comparison does not exceed the predetermined threshold.

3. The printer of claim 1, the data corresponding to the plurality of view further comprising:

computer-aided design (CAD) data of the object to be formed on the planar member.

4. The printer of claim 1, the at least one interferometer further comprising:

a plurality of interferometers, each of the interferometers in the plurality of interferometers being oriented differently than the at least one ejector with reference to the object being formed on the planar member.

5. The printer of claim 4 wherein each interferometer in the plurality of interferometers corresponds to a view in the data corresponding to the plurality of views of the object being formed.

7. The system of claim 5, the material remover further comprising:

a drill.

6. A vibratory component tuning system comprising:

a member configured for mounting a vibratory component;

an interferometer that generates signals corresponding to changes in a surface of the vibratory component as the vibratory component is operated to vibrate;

an actuator operatively connected to the interferometer and configured to move the interferometer along the vibratory component mounted to the member as the vibratory component is operated to vibrate;

an ejector configured to eject material that adheres to the vibratory component mounted to the member;

a material remover configured to remove material from the vibratory component mounted to the member; and

a controller operatively connected to the interferometer, the actuator, the ejector, and the material remover, the controller being configured to;

operate the vibratory component mounted to the member;

operate the actuator to move the interferometer along the surface of the vibratory component;

generate a velocity profile corresponding to vibration of the vibratory component at a plurality of positions along the vibratory component;

identify a position on the vibratory component where material is to be removed or added to the vibratory component; and

operate the material remover to remove material or the ejector to add material to the vibratory component at the identified position to tune the vibratory component to enable the vibratory component to vibrate at a predetermined frequency and velocity set point.

8. The system of claim 6, the ejector further comprising:

a printhead configured to eject material from a reservoir pneumatically connected to the printhead.

9. The system of claim 6, the member being further configured for mounting a transducer as the vibratory component.

10. The system of claim 6, the member being further configured for mounting and rotating the vibratory component.