DYNAMIC IN-FLIGHT CHARACTERIZATION OF BUILD MATERIAL IN A 3D PRINTER AND SYSTEM AND METHODS THEREOF
A system and method of characterizing drops of printing material in a 3D printer is disclosed, which includes ejecting a drop from a nozzle of an ejector in the 3D printer, intersecting the drop with a beam while the drop is in-flight, and determining one or more physical characteristics of the drop. The system and method may include where the drop intersects the beam between the nozzle and a substrate of the 3D printer or the drop intersects the beam between the nozzle and a top surface of a part printed by the 3D printer. The beam is located between an emitter and a detector are each positioned external to one or more side walls of a 3D printer. A physical characteristic of the drop may include drop size, drop shape, or drop mass and comparison with a reference.
1 . A method of characterizing drops of printing material in a 3D printer, comprising:
ejecting a drop from a nozzle of an ejector in the 3D printer;
intersecting the drop with a beam while the drop is in-flight; and
determining one or more physical characteristics of the drop.
2 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein the drop intersects the beam between the nozzle and a substrate of the 3D printer.
3 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein the drop intersects the beam between the nozzle and a top surface of a part printed by the 3D printer.
4 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein the beam is in a horizontal orientation.
5 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein the beam is located between an emitter and a detector are each positioned external to one or more side walls of a 3D printer.
6 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein a physical characteristic of the drop comprises drop size.
7 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein a physical characteristic of the drop comprises drop shape.
8 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein a physical characteristic of the drop comprises drop mass.
9 . The method of characterizing drops of printing material in a 3D printer of claim 1 , further comprising comparing the one or more physical characteristics of the drop with a reference.
10 . The method of characterizing drops of printing material in a 3D printer of claim 9 , further comprising determining a defect by comparing one or more physical characteristics of the drop with a reference.
11 . The method of characterizing drops of printing material in a 3D printer of claim 1 , further comprising pausing one or more printing operations.
12 . The method of characterizing drops of printing material in a 3D printer of claim 1 , further comprising correcting a defect in a drop ejected by the 3D printer.
13 . The method of characterizing drops of printing material in a 3D printer of claim 1 , wherein the print material comprises aluminum.
14 . A method of characterizing drops of printing material in a 3D printer, comprising:
intersecting a collimated laser beam from an emitter with a drop of printing material;
detecting the drop of printing material with a detector; and
analyzing one or more physical characteristics of the drop of printing material.
15 . The method of characterizing drops of printing material in a 3D printer of claim 14 , wherein a physical characteristic of the drop comprises drop size, drop shape, drop mass, or a combination thereof.
16 . The method of characterizing drops of printing material in a 3D printer of claim 14 , wherein the drop of printing material intersects the collimated laser beam while the drop is in-flight.
17 . The method of characterizing drops of printing material in a 3D printer of claim 14 , further comprising comparing the one or more physical characteristics of the drop with a reference.
18 . The method of characterizing drops of printing material in a 3D printer of claim 14 , further comprising determining a defect by comparing one or more physical characteristics of the drop with a reference.
19 . A printing system, comprising:
a substrate;
an ejector for jetting a liquid print material onto the substrate; and
a 2-dimensional beam sensor, wherein a beam emitted by the 2-dimensional beam sensor measures a drop of the liquid printing material when the drop is between the ejector and the substrate.
20 . The printing system of claim 19 , wherein the beam emitted by the 2-dimensional beam sensor measures the drop of the liquid printing material when the drop is between the ejector and a surface of a part being printed by the printing system.
21 . The printing system of claim 19 , wherein the liquid print material comprises a metal, a metallic alloy, or a combination thereof.
22 . The printing system of claim 21 , wherein the liquid print material comprises aluminum.
23 . The printing system of claim 19 , wherein the ejector further comprises:
a structure defining an inner cavity; and
a nozzle orifice in connection with the inner cavity and configured to eject one or more drops of liquid print material.
24 . The printing system of claim 19 , further comprising:
an inner chamber located below the ejector and above the substrate; and
an outer chamber area comprising an emitter and a detector of the 2-dimensional beam sensor.
25 . The printing system of claim 19 , further comprising at least one aperture through which the beam passes.
26 . The printing system of claim 25 , further comprising a door configured to intermittently cover the at least one or more aperture.
27 . The printing system of claim 24 , wherein the inner chamber permits no light to enter or escape.