Characterizing meniscus behavior in 3D liquid metal printing

Patent metadata

Field	Value
Publication number	US-11760000-B2
Application number	US-202117314933-A
Country	US
Kind code	B2
Filing date	May 7, 2021
Priority date	May 7, 2021
Publication date	Sep 19, 2023
Grant date	Sep 19, 2023

Abstract

A method includes capturing a video of a plurality of drops being jetted through a nozzle of a printer. The method also includes measuring a signal proximate to the nozzle based at least partially upon the video. The method also includes determining one or more metrics that characterize a behavior of the drops based at least partially upon the signal.

First claim

What is claimed is:

1. A method, comprising:
capturing an image, a video, or both of a plurality of drops being jetted through a nozzle of a printer;
measuring a signal proximate to the nozzle based at least partially upon the image, the video, or both;
determining a meniscus oscillation frequency of the drops in the nozzle based at least partially upon the signal; and
adjusting a parameter of the printer when the meniscus oscillation frequency is outside of a predetermined range.

2. The method of claim 1 , wherein the signal comprises a spatiotemporal variance (STV) signal.

3. The method of claim 1 , further comprising predicting a jetting quality of the printer based at least partially upon the meniscus oscillation frequency.

4. The method of claim 1 , further comprising predicting a stability of the drops based at least partially upon the meniscus oscillation frequency.

5. The method of claim 1 , wherein the parameter comprises a current, a voltage, a pulse length, a voltage versus time waveform, or a combination thereof provided to a coil of the printer that causes the drops to be jetted through the nozzle.

6. The method of claim 1 , wherein the parameter comprises a frequency at which the drops are jetted through the nozzle.

7. The method of claim 1 , further comprising determining a plurality of pulse periods based at least partially upon the signal, wherein each pulse period comprises a portion of the signal between two consecutive drops of the plurality of drops, and wherein the meniscus oscillation frequency is determined based at least partially upon the pulse periods.

8. The method of claim 1 , further comprising generating a pulse-averaged signal based at least partially upon the signal, wherein the meniscus oscillation frequency is determined based at least partially upon the pulse-averaged signal.

9. The method of claim 1 , further comprising generating an amplitude envelope based at least partially upon the signal, wherein the meniscus oscillation frequency is determined based at least partially upon the amplitude envelope.

10. The method of claim 1 , further comprising generating a meniscus carrier signal based at least partially upon the signal, wherein the meniscus oscillation frequency is determined based at least partially upon the meniscus carrier signal.

11. The method of claim 1 , wherein the predetermined range is from 500 Hz to 2 kHz.

12. The method of claim 1 , wherein the predetermined range is from 1 kHz to 1.5 kHz.

13. A method for printing, the method comprising:
capturing a video of a plurality of drops being jetted through a nozzle of a printer;
determining a spatiotemporal variance (STV) signal proximate to a location of the nozzle in the video;
determining a plurality of pulse periods based at least partially upon the STV signal, wherein each pulse period comprises a portion of the STV signal between two consecutive drops of the plurality of drops;
generating a pulse-averaged signal based at least partially upon the plurality of pulse periods;
generating an amplitude envelope based at least partially upon the pulse-averaged signal;
generating a meniscus carrier signal based at least partially upon the pulse-averaged signal, the amplitude envelope, or both;
determining a meniscus oscillation frequency of the drops in the nozzle based at least partially upon the meniscus carrier signal; and
adjusting a parameter of the printer based at least partially upon the meniscus oscillation frequency.

14. The method of claim 13 , wherein generating the amplitude envelope comprises moving a sliding temporal window over the pulse-averaged signal, and wherein the amplitude envelope comprises a difference between local maxima and minima over the sliding temporal window.

15. The method of claim 13 , wherein generating the meniscus carrier signal comprises:
normalizing the pulse-averaged signal to zero mean to produce a normalized pulse-averaged signal; and
dividing the normalized pulse-averaged signal by the envelope amplitude to generate the meniscus carrier signal, wherein the meniscus carrier signal is in a time domain.

16. The method of claim 13 , wherein determining the meniscus oscillation frequency comprises:
converting the meniscus carrier signal from a time domain to a frequency domain; and
locating a peak of the meniscus carrier signal in the frequency domain.

17. A method for characterizing a behavior of a plurality of drops of a liquid while the drops are positioned at least partially within a nozzle of a printer, the method comprising:
capturing a video of the plurality of drops of the liquid being jetted through the nozzle of the printer;
determining a location of the nozzle in the video;
determining a spatiotemporal variance (STV) signal at the location of the nozzle in the video;
determining when the drops are jetted through the nozzle by:
identifying a neighboring location proximate to the location of the nozzle;
determining a second STV signal at the neighboring location; and
determining that the drops are jetted through the nozzle in response to increases in the second STV signal, which indicates that the drops have been jetted through the nozzle and are passing through the neighboring location;

determining a plurality of pulse periods based at least partially upon the determination of when the drops are jetted through the nozzle, wherein each pulse period comprises a portion of the STV signal between two consecutive drops of the plurality of drops;
generating a pulse-averaged signal by aligning and averaging the plurality of pulse periods;
generating an amplitude envelope by moving a sliding temporal window over the pulse-averaged signal, wherein the amplitude envelope comprises a difference between local maxima and minima over the sliding temporal window;
generating a meniscus carrier signal by:
normalizing the pulse-averaged signal to zero mean to produce a normalized pulse-averaged signal; and
dividing the normalized pulse-averaged signal by the envelope amplitude to generate the meniscus carrier signal, wherein the meniscus carrier signal is in a time domain;

determining a meniscus oscillation frequency of menisci on lower surfaces of the drops when the drops are positioned at least partially in the nozzle by:
converting the meniscus carrier signal from the time domain to a frequency domain; and
locating a peak of the meniscus carrier signal in the frequency domain; and

adjusting a parameter of the printer based at least partially upon the meniscus oscillation frequency.

18. The method of claim 17 , wherein the STV signal is determined within a M×M×K spatiotemporal window within the video, where M represents a spatial extent in pixels, and K represents a number of frames in the video.

19. The method of claim 17 , wherein adjusting the parameter comprises adjusting a power provided to one or more coils of the printer, wherein the power being provided to the coils causes the drops to be jetted through the nozzle.

20. The method of claim 17 , wherein adjusting the parameter comprises adjusting a frequency at which the drops are jetted through the nozzle.

21. The method of claim 17 , wherein adjusting the parameter comprises adjusting a temperature of the liquid in the printer.

Assignees

• Xerox Corp

Inventors

• Bala Raja
• Gopalkrishna Vijay Kumar Baikampady
• Ramesh Palghat
• Mantell David Allen
• Gulvin Peter Michael
• Cellura Mark A

Classifications

• B29C64/112 Primary

  using individual droplets, e.g. from jetting heads · CPC title

• B29C64/209

  Heads; Nozzles · CPC title

• B29C64/393

  for controlling or regulating additive manufacturing processes · CPC title

• B33Y50/02

  for controlling or regulating additive manufacturing processes · CPC title

• B22F10/22

  Direct deposition of molten metal · CPC title