System and method for test pattern formation during three-dimensional object printing

A method of operating a three-dimensional object printer comprising:

• operating with a controller a support material dispenser to form a first layer of a support material on a first region of a member;
• operating with the controller a first plurality of ejectors in a first printhead to eject a portion of a first predetermined pattern of drops of a build material onto the first layer of the support material to form a first portion of a first test pattern;
• operating with the controller an image sensor to generate scanned image data of the first portion of the first test pattern;
• operating with the controller the support material dispenser to form at least one additional layer of the support material on the first region of the member over the first layer of the support material and the first portion of the first test pattern;
• operating with the controller the first plurality of ejectors in the first printhead to eject a portion of a second predetermined pattern of drops of the build material onto the at least one additional layer to form a second portion of the first test pattern;
• operating with the controller the image sensor to generate scanned image data of the second portion of the test pattern;
• and
• identifying with the controller at least one inoperable ejector in the first printhead with reference to the scanned image data of the first portion of the first test pattern and the scanned image data of the second portion of the first test pattern.

A method of operating a three-dimensional object printer comprising:

• operating with a controller a first plurality of ejectors in a first printhead to form a first layer of a first build material on a first region of a member;
• operating with the controller a second plurality of ejectors in a second printhead to eject a portion of a first predetermined pattern formed from drops of a second build material onto the first layer of the first build material to form a first portion of a first test pattern;
• operating with the controller an image sensor to generate scanned image data of the first portion of the first test pattern;
• operating with the controller the first plurality of ejectors in the first printhead to form at least one additional layer of the first build material on the first region of the member over the first layer of the build material and the first portion of the first test pattern;
• operating with the controller the second plurality of ejectors in the second printhead to eject a portion of a second predetermined pattern of drops of the second build material onto the at least one additional layer of the first build material to form a second portion of the first test pattern;
• operating with the controller the image sensor to generate scanned image data of the second portion of the test pattern;
• and
• identifying with the controller at least one inoperable ejector in the first printhead with reference to the scanned image data of the first portion of the first test pattern and the scanned image data of the second portion of the first test pattern.