Layer-to-Layer Predictive Control of Inkjet 3-D Printing

Inyang-Udoh, Uduak; Guo, Yijie; Peters, Joost; Oomen, Tom; Mishra, Sandipan

doi:10.1109/tmech.2020.2999873

Cited by 15 publications

(6 citation statements)

References 23 publications

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“…We used layer-by-layer stacking to fabricate the biomimetic ECM (ref. 28 , 29 ). The final ECM microstructure is composed of multiple stacked layers of the cured GelMA hydrogel, where each cured layer was obtained during an independent printing cycle.…”

Section: Methodsmentioning

confidence: 99%

Accurate modulation of photoprinting under stiffness imaging feedback for engineering ECMs with high-fidelity mechanical properties

Wang

Dong

et al. 2022

Microsyst Nanoeng

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Engineered extracellular matrices (ECMs) that replicate complex in-vivo features have shown great potential in tissue engineering. Biocompatible hydrogel microstructures have been widely used to replace these native ECMs for physiologically relevant research. However, accurate reproduction of the 3D hierarchical and nonuniform mechanical stiffness inside one integrated microstructure to mimic the complex mechanical properties of native ECMs presents a major challenge. Here, by using digital holographic microscopy (DHM)-based stiffness imaging feedback, we propose a novel closed-loop control algorithm to achieve high-accuracy control of mechanical properties for hydrogel microstructures that recapitulate the physiological properties of native ECMs with high fidelity. During photoprinting, the photocuring area of the hydrogel is divided into microscale grid areas to locally control the photocuring process. With the assistance of a motorized microfluidic channel, the curing thickness is controlled with layer-by-layer stacking. The DHM-based stiffness imaging feedback allows accurate adjustment of the photocuring degree in every grid area to change the crosslinking network density of the hydrogel, thus enabling large-span and high-resolution modulation of mechanical properties. Finally, the gelatin methacrylate was used as a typical biomaterial to construct the high-fidelity biomimetic ECMs. The Young’s modulus could be flexibly modulated in the 10 kPa to 50 kPa range. Additionally, the modulus gradient was accurately controlled to within 2.9 kPa. By engineering ECM with locally different mechanical properties, cell spreading along the stiff areas was observed successfully. We believe that this method can regenerate complex biomimetic ECMs that closely recapitulate in-vivo mechanical properties for further applications in tissue engineering and biomedical research.

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Section: Methodsmentioning

confidence: 99%

Accurate modulation of photoprinting under stiffness imaging feedback for engineering ECMs with high-fidelity mechanical properties

Wang

Dong

et al. 2022

Microsyst Nanoeng

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“…Ultraviolet (UV) inkjet printing is becoming the focus of industry applications as a contactless, pressure-free, plate-free UV printing and reproduction technology. The UV curing process instantly deposits a hardened layer of ink and achieves directed adherence to the surface on substrate materials to display digital texture image designs [2,3]. In this process, the UV-curable ink used in the inkjet printing coatings is a typical photo-curable material.…”

Section: Introductionmentioning

confidence: 99%

Effects of MDF Substrate Surface Coating Process on UV Inkjet Print Quality

2023

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The structural properties and whiteness of the substrate surface markedly effect printing quality and are closely related to the primer coating processes. Herein, four different roller coating schemes were applied on MDF surfaces to change their structural properties and color, and the whiteness, gloss, and roughness properties of the substrate surfaces were characterized for UV inkjet printing. Data analysis was conducted to explore the effects of these variables on the color reproduction, relative contrast, and printing gloss of the MDF substrates. The results showed that, according to CMYK, L*a*b* values and spectral reflectance data, the finishing of the MDF substrate with a 40 g/m2 layer of transparent primer combined with three layers of white primer at 20 g/m2 per roll coating layer had the best color reproduction effect for UV inkjet printing. Regarding the effects of relative contrast, the correlation with whiteness and glossiness was significant, while the correlation with glossiness was minor. The inkjet printing gloss value was positively correlated with substrate primer surface whiteness, while it was negatively correlated with roughness. When the surface whiteness of the substrate was relatively high, the roughness was lower and the printing effects were glossier. We sought to optimize the printing effects of all aspects of the MDF substrate by primer coating. The results of this work provide a feasible application method to improve printing quality and enhance the added value of low-quality boards, as well as to further expand the application of UV inkjet printing in the wood decoration market.

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“…There are several bead geometry control systems that employ an MPC approach in conventional welding areas (Li & Zhang, 2014;Stoyanov & Bailey, 2017). MPC approaches have also been employed in non-metal AM, powder-based metal AM and conventional gas tungsten arc welding (GTAW) processes to achieve a similar action of layer-by-layer control (Inyang-Udoh et al, 2020;Liu et al, 2019). These approaches are extended in this work by implementing a multi-input multi-output (MIMO) MPC strategy to output welding parameters between each layer of the fabrication process.…”

Section: Introductionmentioning

confidence: 99%

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

Polden

et al. 2022

J Intell Manuf

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Improving the geometric accuracy of the deposited component is essential for the wider adoption of wire arc additive manufacturing (WAAM) in industries. This paper introduces an online layer-by-layer controller that operates robustly under various welding conditions to improve the deposition accuracy of the WAAM process. Two control strategies are proposed and evaluated in this work: A PID algorithm and a multi-input multi-output model-predictive control (MPC) algorithm. After each layer of deposition, the deposited geometry is measured using a laser scanner. These measurements are compared against the CAD model, and geometric errors are then compensated by the controller, which generates a new set of welding parameters for the next layer. The MPC algorithm, combined with a linear autoregressive (ARX) modelling process, updates welding parameters between successive layers by minimizing a cost function based on sequences of input variables and predicted responses. Weighting coefficients of the ARX model are trained iteratively throughout the manufacturing process. The performance of the designed control architecture is investigated through both simulation and experiments. Results show that the real-time control performance is improved by increasing the complexity of implemented control algorithm: controlled geometric fluctuations in the test component were reduced by 200% whilst maintaining fluctuations within a 3 mm limit under various welding conditions. In addition, the adaptiveness of designed control strategy is verified by accurately controlling the fabrication of a part with complex geometry.

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Layer-to-Layer Predictive Control of Inkjet 3-D Printing

Cited by 15 publications

References 23 publications

Accurate modulation of photoprinting under stiffness imaging feedback for engineering ECMs with high-fidelity mechanical properties

Accurate modulation of photoprinting under stiffness imaging feedback for engineering ECMs with high-fidelity mechanical properties

Effects of MDF Substrate Surface Coating Process on UV Inkjet Print Quality

Layer-by-layer model-based adaptive control for wire arc additive manufacturing of thin-wall structures

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