Method and system for operating a metal drop ejecting three-dimensional (3D) object printer to compensate for drop size variations

A method for operating a three-dimensional (3D) metal object manufacturing system configured to eject melted metal drops comprising:

• generating image data of a metal object being formed by the melted metal drops ejected by the 3D metal object manufacturing system prior to completion of the metal object;
• comparing the generated image data of the metal object to original 3D object design data to identify a difference;
• identifying a displacement error as the identified difference when the identified difference is outside a predetermined difference range;
• modifying machine-ready instructions by changing drop spacing parameters identified in the machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement error the drop spacing parameters being changed by using a non-linear function;
• and
• operating the 3D metal object manufacturing system using the modified machine-ready instructions.

A method for operating a three-dimensional (3D) metal object manufacturing system configured to eject melted metal drops comprising:

• generating image data of a metal object being formed by the melted metal drops ejected by the 3D metal object manufacturing system prior to completion of the metal object;
• comparing the generated image data of the metal object to original 3D object design data to identify a difference;
• identifying a displacement error as the identified difference when the identified difference is outside a predetermined difference range;
• modifying machine-ready instructions by changing drop spacing parameters identified in the machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement error;
• setting a maximum frequency for drop firing within a layer;
• modifying a speed of movement for an ejector in the machine-ready instructions to ensure a frequency of ejection from the ejector does not exceed the maximum frequency;
• and
• operating the 3D metal object manufacturing system using the modified machine-ready instructions.

A three-dimensional (3D) metal object manufacturing system comprising:

• a printhead configured to eject drops of melted metal toward a platform;
• an optical sensor configured to generate image data of a metal object being formed by the 3D metal object manufacturing system on the platform prior to completion of the metal object;
• and
• a controller operatively connected to the optical sensor and the printhead, the controller being configured to:
• compare the generated image data of the metal object to original 3D object design data to identify a difference;
• identify a displacement error as the identified difference when the identified difference is outside a predetermined difference range;
• modify machine-ready instructions by changing drop spacing parameters identified in the machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement error, the drop spacing parameters being changed by using a linear function;
• and
• operate the 3D metal object manufacturing system using the modified machine-ready instructions.

A three-dimensional (3D) metal object manufacturing system comprising:

• a printhead configured to eject drops of melted metal toward a platform;
• an optical sensor configured to generate image data of a metal object being formed by the 3D metal object manufacturing system on the platform prior to completion of the metal object;
• and
• a controller operatively connected to the optical sensor and the printhead, the controller being configured to:
• compare the generated image data of the metal object to original 3D object design data to identify a difference;
• identify a displacement error as the identified difference when the identified difference is outside a predetermined difference range;
• modify machine-ready instructions by changing drop spacing parameters identified in the machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement error, the drop spacing parameters being changed by using a non-linear function;
• and
• operate the 3D metal object manufacturing system using the modified machine-ready instructions;
• change the drop spacing parameters using a non-linear function.

A three-dimensional (3D) metal object manufacturing system comprising:

• a printhead configured to eject drops of melted metal toward a platform;
• an optical sensor configured to generate image data of a metal object being formed by the 3D metal object manufacturing system on the platform prior to completion of the metal object;
• and
• a controller operatively connected to the optical sensor and the printhead, the controller being configured to:
• compare the generated image data of the metal object to original 3D object design data to identify a difference;
• identify a displacement error as the identified difference when the identified difference is outside a predetermined difference range;
• modify machine-ready instructions by changing drop spacing parameters identified in the machine-ready instructions for forming metal object layers not yet formed to compensate for the identified displacement error;
• set a maximum frequency for drop firing within a layer;
• and
• modify a speed of movement for the printhead in the machine-ready instructions to ensure a frequency of ejection from the printhead does not exceed the maximum frequency;
• and
• operate the 3D metal object manufacturing system using the modified machine-ready instructions.