3D Model Design Rules for Precise Microfeature Representation in 3D Inkjet Printing Data

Three-dimensional inkjet printing (3D-IJ) is an additive manufacturing technology with great potential for manufacturing microdevices and systems using functional inks. To improve the sustainability of this technology, reducing material consumption is crucial, which can be achieved by minimizing failed prints due to defective sliced images or improper printing conditions. This study aims to investigate how a 3D model should be designed and placed on the slicer to ensure an exact representation of the geometry in the slice images. Several test specimens, consisting of multiple square and cylindrical elements, are sliced, modified, and assessed with regard to (I) positioning on the slicer platform, (II) unit of design (inch or millimeter), (III) alignment of the elements within the 3D model, and (IV) the overall size of the model. The results demonstrate that when multiple specimens are placed throughout the platform, their positions should be defined according to the size of one pixel, determined by the image resolution, to ensure consistent slicing outcomes. Additionally, to accurately represent features as small as one pixel in the sliced images, the dimensions of the designed elements should be an integer multiple of the pixel size, aligned to one side, and the total size should be an even number of pixels. ... mehrFinally, it can be concluded that understanding the conditions for generating exact print data enhances the sustainable potential of 3D-IJ.