Systems for combined laser fabrication and ink printing

Abstract

Disclosed embodiments include a CNC / print system with (i) a laser cutting subassembly (220), (ii) an ink printing subassembly (222), (iii) a housing (202) with laser blocking components configured to prevent laser light from the laser cutting subassembly from escaping the housing during operation of the laser cutting subassembly, (iv) a material feeding subassembly (242,243,244,246,247,248) configured to move material (230) through the housing when processing the material by the laser cutting subassembly and the ink printing subassembly, (v) one or more processors, (vi) computer memory storing program instructions executable by the one or more processors (223) to cause the CNC / print system to perform various functions including, while a region of material is positioned within the housing, (a) applying laser power to the region of material positioned within the housing via the laser cutting subassembly and (b) applying ink to the region of material positioned within the housing via the ink printing subassembly.

Description

SYSTEM FOR COMBINED LASER FABRICATION AND INK PRINTINGCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to (i) U.S. Prov. App. 63 / 676,057 titled “Systems for Combined Laser Fabrication and Ink Printing,” filed on Jul. 26, 2024, and currently pending; (ii) U.S. Prov. App. 63 / 742,831 titled “Systems for Combined Laser Fabrication and Ink Printing,” filed on Jan. 7, 2025, and currently pending; and (iii) U.S. Prov. App. 63 / 804,587 titled “Systems for Combined Laser Fabrication and Ink Printing,” filed on May 12, 2025, and currently pending. The entire contents of U.S. Prov. Apps. 63 / 676,057; 63 / 742,831; and 63 / 804,587 are incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] The subject matter described herein relates generally to computer-controlled fabrication, including computer numerically controlled (CNC) machines equipped with lasers and ink printing capabilities.OVERVIEW

[0003] Disclosed embodiments include CNC machines equipped with laser cutting and ink printing capabilities, sometimes referred to herein as CNC / print systems.

[0004] In some embodiments, a CNC / print system includes, among other components, one or more (or all) of (i) a laser cutting subassembly, (ii) an ink printing subassembly, (iii) a housing that includes one or more laser blocking components configured to prevent laser light from the laser cutting subassembly from escaping the housing during operation of the laser cutting subassembly, and (iv) a material feeding subassembly configured to move material through an interior portion of the housing when processing the material by the laser cutting subassembly and the ink printing subassembly. Some CNC / print system embodiments additionally include (i) one or more processors, and (ii) tangible, non-transitory computer readable media comprising program instructions that, when executed by the one or more processors, cause the CNC / print system to perform functions.

[0005] In some examples, the functions performed by the CNC / print system include, among other features, while a region of material is positioned within the housing of the CNC / print system, (i) applying laser power to the region of material positioned within thehousing via the laser cutting subassembly and (ii) applying ink to the region of material positioned within the housing via the ink printing subassembly.

[0006] In some embodiments, the CNC / print system includes one or more cameras. The one or more cameras may be positioned on one or more of the laser cutting subassembly, the ink printing subassembly, and / or elsewhere within the housing of the CNC / print system. In operation, the one or more cameras are configured to capture image data for performing several different functions, such as, for example, (i) detecting type of material processed by the CNC / print system, e.g., based on a barcode (e.g., for Proofgrade® material provided by Glowforge, Inc.) on the surface of the material, grains or other patterns on the surface of the material, or other indications present in an image of the material to be processed, (ii) performing calibration of one or both of the laser cutting subassembly or the ink printing subassembly, (iii) detecting anomalous conditions (e.g., misaligned / misdirected laser beam, smoke, fire, etc.) within the housing, and / or (iv) monitoring the status and progress of a fabrication project implemented by the CNC / print system.

[0007] Some embodiments that include using the one or more cameras in connection with detecting the type of material to be processed may additionally include adjusting one or more operational parameters of one or both of the laser cutting subassembly and / or the ink printing subassembly based on the detected material. For example, if the material to be processed is 3 millimeter Proofgrade acrylic, then the CNC / print system may adjust (i) the power level of the laser cutting subassembly and the speed of the material feeding subassembly or other parameters to control both the laser power and the dwell time of the laser over the material during processing and / or (ii) the amount of ink deposited by the ink printing subassembly and the UV curing time of the ink, based on the detected material.

[0008] In some embodiments, the CNC / print system is configured to adjust laser cutting parameters based on characteristics of ink that has been (or will be) applied to the material by the ink printing subassembly. For example, the CNC / print system may adjust one or more of (i) laser power level, (ii) laser pulse frequency, (iii) laser dwell time, (iv) number of laser passes, and / or (v) laser focus parameters based on properties of ink present on the material surface, including but not limited to ink color, ink density, ink thickness, ink composition, and / or ink pattern coverage.

[0009] In some embodiments, one or more internal sensors (e.g., one or more cameras mounted within the housing) are configured to detect ink characteristics on the material surface. In some embodiments, the CNC / print system may analyze image data from one or more cameras mounted within the housing to determine ink colors, patterns, and densities present in regions to be processed by the laser cutting subassembly. For example, the CNC / print system may detect that a first region contains dense blue ink coverage while a second region contains sparse red ink coverage, and adjust laser parameters accordingly when processing each region. In other embodiments, the CNC / print system may include one or more spectral sensors configured to measure specific wavelengths absorbed or reflected by inks present on the material surface. For example, the CNC / print system may use spectral sensor data to determine ink compositions and tune laser parameters based on absorption characteristics of the determined ink compositions according to the laser wavelength used in the CNC / print system.

[0010] In some embodiments, the CNC / print system maintains data about ink properties based on the ink printing instructions used to apply the ink. For example, when processing a design file containing both printing and cutting instructions, the CNC / print system may track which regions will receive which inks and automatically adjust laser parameters for those regions based on stored data about laser settings for different ink types and colors.

[0011] In some embodiments, the CNC / print system may maintain a database of selected laser parameter profiles for different combinations of base materials and ink characteristics. For example a database may be used to identify target power variations when cutting through a base material with different ink. For example, it may be determined that when cutting through blue ink on acrylic, the laser power should be increased by 15% compared to cutting through unprinted regions, while red ink may require only a 5% power increase. These profiles may be updated over time based on cutting results and feedback from the one or more sensors monitoring the cutting process.

[0012] Some embodiments include the ability to automatically generate and maintain different parameter profiles for different ink formulations used in the ink printing subassembly. When new ink formulations are introduced (e.g., when ink cartridges are replaced), the CNC / print system may perform test cuts through samples of the new ink to optimize laser parameters specifically for that formulation.

[0013] In some embodiments, the CNC / print system is configured to adjust laser parameters dynamically during cutting based on real-time feedback about the cutting progress through inked regions. For example, one or more sensors (e.g., cameras mounted inside the housing, etc.) may monitor the depth, width, or quality of the cut being achieved and the CNC / print system may adjust laser parameters accordingly to maintain consistent cutting results regardless of ink presence or characteristics.

[0014] Some embodiments that include using the one or more cameras in connection with performing calibration of one or both of the laser cutting subassembly or the ink printing subassembly include printing registration marks on the surface of material with the ink printing subassembly and cutting registration marks on the surface of the material with the laser cutting subassembly so that the ink printing subassembly and the laser cutting subassembly can align their axes of operation. In some embodiments that employ the single and dual gantry arrangements described in further detail herein, one or more spatial relationships between the laser cutting subassembly and the ink printing subassembly may be fixed, and thus known. Since the actual spatial relationship is known, the registration marks can be compared to see whether and to the extent which the actual spatial relationship is consistent with the expected spatial relationship.

[0015] In some embodiments, the CNC / print system implements an iterative calibration process using cut patterns and scanning feedback. The system may be configured to (i) cut or engrave a first calibration pattern into the material via the laser cutting subassembly, (ii) scan the resulting pattern via one or more cameras or sensors to analyze the results, and (iii) generate calibration adjustments based on the analysis.

[0016] For example, the first calibration pattern may include, among other features, (i) a series of cuts or engravings of varying depth achieved by varying laser power and / or dwell time, (ii) a series of parallel lines cut at different speeds and / or power settings, (iii) a grid pattern with known spacing between elements, (iv) circular or curved patterns to calibrate motion system accuracy, and / or (v) cuts of varying width achieved through different focus settings or multiple passes.

[0017] In some implementations, after cutting a first calibration pattern, one or more cameras (e.g., cameras mounted within the housing) capture high-resolution images of the results. The CNC / print system can analyze these images to measure characteristics including butnot limited to (i) cut depth, (ii) cut width, (iii) edge quality, (iv) spacing accuracy, (v) geometric accuracy of shapes, and / or (vi) presence of unwanted burning or charring. This analysis may employ computer vision techniques including edge detection, pattern matching, and dimensional measurement. Based on the analysis results, the CNC / print system may generate calibration adjustments which may include, for example, modifications to (i) laser power output, (ii) motion system positioning, (iii) focal length calculations, (iv) speed settings, and / or (v) other operational parameters. The system may further perform additional test cuts to verify the calibration adjustments.

[0018] For embodiments that include both laser cutting and ink printing capabilities, the calibration process may additionally include (i) printing a test pattern via the ink printing subassembly, (ii) cutting or engraving through or adjacent to the printed pattern, and (iii) analyzing the combined results to calibrate the spatial relationship and operational parameters of both subassemblies. The test pattern may include registration marks, color blocks, or other features designed to optimize both printing and cutting operations.

[0019] In some embodiments, the CNC / print system may maintain a history of calibration results over time to detect trends or degradation in system performance. For example, the system may track changes in required laser power settings or deterioration in cut quality to predict maintenance needs or component replacement intervals.

[0020] In some embodiments, the calibration process includes environmental sensors that monitor temperature, humidity, or other conditions that may affect cutting or printing performance. The system may automatically initiate recalibration when environmental conditions change beyond specified thresholds.

[0021] In some embodiments, the CNC / print system may implement different calibration processes for different materials or material categories. For example, the calibration patterns and analysis criteria used for wood may differ from those used for acrylic or paper. The CNC / print system also may maintain separate calibration profiles for different materials and automatically apply the appropriate profile based on material detection.

[0022] In some embodiments, the calibration process includes user feedback mechanisms. For example, after performing test cuts or prints, the system may present results to the user via a display or user interface and allow the user to accept or adjust the proposedcalibration settings. The system may also maintain different calibration profiles for different users or use cases.

[0023] In operation, the CNC / print system according to some embodiments is configured to (i) apply ink to the surface of material via the ink printing subassembly (i.e., perform “ink printing”) and (ii) perform laser processing (e.g., cutting, engraving, etching, scoring, etc.) on the surface of the material via the laser cutting subassembly. The disclosed CNC / print systems can be configured to perform ink printing and laser processing in a variety of configurations, including but not limited to, for example, any combination of: (i) performing ink printing one single side of a material, (ii) performing ink printing on two sides of the material, (iii) performing laser processing on one side of the material, and / or (iv) performing laser processing on two sides of the material.

[0024] In some embodiments, the CNC / print system additionally includes a scanner subassembly. In some such embodiments, the CNC / print system is configured to, among other features, (i) capture image data corresponding to an item via the scanner subassembly, and (ii) process the material with one or both of the laser cutting subassembly or the ink printing subassembly based at least in part on the image data corresponding to the item. In some embodiments, the scanner subassembly is additionally configured to perform material detection and system calibration functions similar to the one or more cameras described herein. For example, the scanner subassembly may be configured to (i) detect type of material processed by the CNC / print system, e.g., based on a barcode (e.g., for Proofgrade® material provided by Glowforge, Inc.) on the surface of the material, grains or other patterns on the surface of the material, or other indications present in an image of the material to be processed, (ii) perform calibration of one or both of the laser cutting subassembly or the ink printing subassembly by analyzing registration marks or calibration patterns, (iii) detect ink characteristics on the material surface, including ink colors, patterns, and densities present in regions to be processed by the laser cutting subassembly, and / or (iv) monitor the status and progress of a fabrication project implemented by the CNC / print system. In some examples, the scanner subassembly may analyze image data to determine ink compositions and material properties, enabling the CNC / print system to adjust operational parameters of one or both of the laser cutting subassembly and / or the ink printing subassembly based on the detected material and ink characteristics.

[0025] In some example embodiments, the CNC / print system additionally includes a debris removal subassembly. In some such embodiments, the debris removal subassembly includes one or more (or all) of: (i) a wiper assembly configured to wipe debris from a region of a surface of the material after the system has processed the region with the laser cutting subassembly; (ii) a tray arranged to capture debris removed from the region of the material by the wiper assembly; and (iii) an exhaust system comprising (a) one or more filters, (b) one or more fans configured to pull air containing debris from within the housing through the one or more filters, and (c) one or more exhaust ports arranged to exhaust air that has been filtered by the one or more filters.

[0026] Some embodiments additionally or alternatively include a specially-configured carriage comprising (i) a laser cutting subassembly, (ii) an ink printing subassembly, (iii) at least one fan, (iv) one or more air passages configured to direct airflow from the at least one fan toward a region of material positioned within the housing where the laser cutting subassembly applies laser power to the region of material, (v) one or more airflow sensors configured to detect whether sufficient airflow is being directed out of the air passages and toward the region of the material positioned within the housing where the laser cutting subassembly applies laser power to the region of material), and (vi) at least one material movement sensor configured to monitor movement of the region of the material positioned within the housing where the ink printing subassembly applies ink to the region of material. In operation, this specially-configured carriage improves both laser cutting and ink printing operations in several ways, including but not limited to reducing the likelihood of fire potentially caused by application of laser energy to the material during processing. In operation, the disclosed systems help to reduce the likelihood of fire by helping monitor and maintain proper material movement through the system while monitoring and maintaining effective air flow. Some embodiments may additionally include one or more temperature sensors configured to monitor a temperature of the region where the laser cutting subassembly is applying laser energy to the material during processing. Some such embodiments may additionally use temperature measurements of the material during processing to adjust the airflow and / or material movement during processing to help further reduce the likelihood of fire.

[0027] The system architecture is scalable across multiple form factors, from desktop units suitable for personal use to production-grade systems for commercial manufacturing. Insome embodiments, the disclosed CNC / print system architecture supports multiple manufacturing variants optimized for different market segments and operational requirements. For example, an entry-level desktop variant may be configured for A4-size material processing, incorporating a diode laser of 5 watts or less. This compact configuration targets personal fabrication and small office environments, providing combined printing and cutting capabilities within a footprint suitable for desktop placement while maintaining full safety enclosure and integrated air handling features.

[0028] In another example, a prosumer tabloid variant extends capabilities to larger format materials, implementing a fiber-fed 20-watt infrared laser system. This configuration uniquely combines roll-feed and flat-bed material handling in a hybrid arrangement, enabling processing of both continuous roll materials and rigid sheet goods within a single system. The fiber-fed architecture allows positioning of the laser source away from the processing area, reducing moving mass and enabling higher speed operation while maintaining precision suitable for professional applications.

[0029] In yet another example, for high-volume production environments, a production sheet-fed variant employs a stationary 100-watt CO2 laser source coupled with a moving galvanometer-based beam steering system. This architecture eliminates the mass and inertia limitations of moving laser heads, enabling rapid processing of sheet materials at industrial speeds. The stationary high-power laser source permits robust cooling and power systems while the galvo provides precise beam positioning across the entire working area, optimizing the system for commercial manufacturing applications requiring both high throughput and precision.

[0030] The details of one or more variations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features and advantages of the subject matter described herein will be apparent from the description and drawings, and from the claims. While certain features of the currently disclosed subject matter may be described for illustrative purposes in relation to performing material edge detection to aid automated manufacturing processes such as a computer numerically controlled fabrication process, it should be readily understood that such features are not intended to be limiting.BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The accompanying drawings, which are incorporated in and constitute a part of this specification, show certain aspects of the subject matter disclosed herein and, together with the description, help explain some of the principles associated with the disclosed implementations.

[0032] FIG. 1A shows an overhead view of an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0033] FIG. IB shows an overhead cutaway view of the example CNC / print system for laser fabrication and ink printing shown in FIG. 1 A according to some embodiments.

[0034] FIG. 1C shows a rear view of the example CNC / print system for laser fabrication and ink printing shown in FIG. 1A according to some embodiments.

[0035] FIG. ID shows a front view of the example CNC / print system for laser fabrication and ink printing shown in FIG. 1A according to some embodiments.

[0036] FIG. 2A shows a side cutaway view of an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0037] Fig. 2B shows aspects of an example material feeding subassembly for use with an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0038] FIG. 3A shows aspects of an example dual gantry subassembly configured to facilitate movement of a laser cutting head and an ink printing head for use with an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0039] FIG. 3B shows aspects of example single gantry subassemblies configured to facilitate movement of a laser cutting head and an ink printing head for use with an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0040] FIG. 3C shows aspects of an example carriage with a laser cutting head and an ink printing head in a side-by-side configuration according to some embodiments.

[0041] FIG. 3D shows aspects of an example carriage with a laser cutting head and an ink printing head in a side-by-side configuration that includes a laser beam routing enclosure according to some embodiments.

[0042] FIG. 3E shows a cutaway view of the example carriage of FIG. 3D with a laser cutting head and an ink printing head in a side-by-side configuration that includes a laser beam routing enclosure according to some embodiments.

[0043] FIG. 3F shows a cutaway view of an alternative example carriage with a laser cutting head positioned on top of an ink printing head according to some embodiments.

[0044] FIG. 3G shows an example carriage with a laser cutting head, a black printhead, and a color printhead according to some embodiments.

[0045] FIG. 3H shows a perspective view of an example carriage with combined airflow detection and material movement monitoring capabilities for fire prevention according to some embodiments.

[0046] FIG. 31 shows a bottom view of an example carriage with combined airflow detection and material movement monitoring capabilities for fire prevention according to some embodiments.

[0047] FIG. 4A shows a block diagram illustrating aspects of selected CNC / print system components in an example CNC / print system for laser fabrication and ink printing according to some embodiments where the laser cutting subassembly and the ink printing subassembly use separate lasers according to some embodiments.

[0048] FIG. 4B shows a block diagram illustrating aspects of selected CNC / print system components in an example CNC / print system for laser fabrication and ink printing according to some embodiments where the laser cutting subassembly and the ink printing subassembly use a common laser according to some embodiments.

[0049] FIG. 5A shows a side cutaway view of an example configuration of a CNC / print system for laser fabrication and ink printing according to some embodiments.

[0050] FIG. 5B shows another example configuration of a CNC / print system for laser fabrication and ink printing according to some embodiments.

[0051] FIG. 6 shows an example of a laser cutting module configured to process material received from an ink printing module according to some embodiments.

[0052] FIG. 7 shows a flowchart illustrating an Al-assisted design method for generating print and cut designs from natural language input according to some embodiments.

[0053] FIG. 8A shows an example user interface for entering natural language design descriptions and selecting art styles for printing with a CNC / print system according to some embodiments.

[0054] FIG. 8B shows an example generated design within the user interface of FIG. 8A based the natural language description of the desired fabrication result along with options to use the generated design or generate additional variations according to some embodiments.

[0055] FIG. 8C shows the generated design from FIG. 8B with a cut outline and a score outline added around the generated design according to some embodiments.

[0056] FIG. 8D shows the generated design from FIG. 8C placed on the sticker material within the user interface according to some embodiments.

[0057] FIG. 8E shows a close up view of the top left comer of the user interface screen in FIG. 8D according to some embodiments.

[0058] FIG. 8F shows a close up view of the right side of the user interface screen in FIG. 8D according to some embodiments.

[0059] FIG. 9A shows a front view of an example CNC / print system implementing the generated design from FIGS. 8A-F onto sticker paper material according to some embodiments.

[0060] FIG. 9B shows the front view of the example CNC / print system while the CNC / print system is performing the cutting and scoring procedures on the sticker paper material to produce the custom-created sticker with the design.

[0061] FIG. 9C shows the front view of the example CNC / print system while the example CNC / print system is outputting the sticker paper after printing, scoring, and cutting the sticker paper to fabricate the custom-created sticker with the design.

[0062] FIG. 9D shows a user removing the custom-created sticker from the sticker paper.

[0063] FIG. 9E shows the user removing the sticker portion of the custom-created sticker from the backing portion of the custom-created sticker.

[0064] FIG. 9F shows the user applying the sticker portion onto a mug after the sticker portion has been removed from the backing portion.

[0065] FIG. 10A shows an example user interface for entering natural language design descriptions and selecting art styles for printing with a CNC / print system according to some embodiments.

[0066] FIG. 10B shows an example generated design within the user interface of FIG. 10A based the natural language description of the desired fabrication result along with options to use the generated design or generate additional variations according to some embodiments.

[0067] FIG. 10C shows a sub-window of the user interface depicting the generated design that was selected by the user in FIG. 10B along with a “Use image as-is” button and an “Adjust artwork” button.

[0068] FIG. 10D shows an editing screen of the user interface via which a user can edit one or more aspects of the generated design.

[0069] FIG. 10E shows an additional editing window for editing the layout and content of the card to be fabricated by the CNC / print system.

[0070] When practical, similar reference numbers denote similar structures, features, or elements.DETAILED DESCRIPTION

[0071] Various examples of systems, devices, and / or methods are described herein. Any embodiment, implementation, and / or feature described herein as being an “example” is not necessarily to be construed as preferred or advantageous over any other embodiment, implementation, and / or feature unless stated as such. Thus, other embodiments, implementations, and / or features may be utilized, and other changes may be made without departing from the scope of the subject matter presented herein. Accordingly, the examples described herein are not meant to be limiting. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations. Further, unless the context suggests otherwise, the features illustrated in each of the figures may be used in combination with one another. Thus, the figures should be generally viewed as component aspects of one or more overall embodiments, with the understanding that not all illustrated features are necessary for each embodiment. Additionally, any enumeration of elements, blocks, or steps in this specification or the claims is for purposes of clarity. Thus, such enumeration should not be interpreted to require or imply that these elements, blocks, or steps adhere to a particular arrangement or are carried out in a particular order. Further, terms such as “A coupled to B” or “A is mechanically coupled to B” do not require members A and B to be directly coupled to one another. It is understood that various intermediate members may be utilized to “couple” membersA and B together. Moreover, terms such as “substantially” or “about” that may be used herein, are meant that the recited characteristic, parameter, or value need not be achieved exactly but that deviations or variations, including, for example, tolerances, measurement error, measurement accuracy limitations and other factors known to skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.I. System Overview and Components

[0072] FIG. 1A shows an overhead view of an example CNC / print system 100 for laser fabrication and ink printing according to some embodiments.

[0073] The CNC / print system 100 includes a housing 102 with a top 104 that lifts to reveal an interior portion of the housing 102, and a material ingress 106 via which material to be processed by the CNC / print system 100 can be fed into the interior portion of the housing 102 for processing by one or both of a laser cutting subassembly and / or an ink printing subassembly contained within the housing 102.

[0074] The housing 102 is configured to prevent laser light from the laser cutting subassembly from escaping the housing 102 during operation of the laser cutting subassembly, such as when the CNC / print system 100 is processing material with the laser cutting subassembly. In some examples, the housing 102 is or comprises a Class 1 compliant enclosure configured to block laser light (e.g., laser light between about 350 nm - 500 nm in wavelength having a laser power between about 500 mW - 100 W).

[0075] In some embodiments, the top 104 lifts to reveal a scanner configured to capture image data corresponding to an item placed within the scanner. For example, in embodiments where the top 104 lifts to reveal a scanner, the scanner is configured to accommodate a piece of paper or sheet of wood, plastic, cardboard, or other material. In operation, the scanner is configured to obtain image data corresponding to images, designs, or printed words on the paper, wood, plastic, cardboard or other material placed into the scanner. In some instances, CNC / print system 100 can also use the image data to identify a material type (e.g., determining whether the material type is wood (e.g., based on wood grain in the image), metal (e.g., based on reflectivity in the image), glass (e.g., based on transmissivity / reflectivity in the image), acrylic (e.g., based on color in the image), or any other type of material (e.g., based on a bar code, QR code, or similar identifier on the surface of the material). And the CNC / print system 100 is configured toreproduce the image data, in whole or in part, via laser fabrication (with the laser cutting subassembly), ink printing (with the ink printing subassembly), or a combination of both. In some embodiments, the top 104 lifts to access the interior portion of the housing 102. In still further embodiments, the top 104 lifts to reveal the bed of the scanner, and the bed of the scanner can be further lifted / removed to access the interior portion of the housing 102.

[0076] In some embodiments, the CNC / print system integrates artificial intelligence (Al) and machine learning (ML) capabilities to enhance processing of scanned images and generation of fabrication instructions. The CNC / print system may, for example, implement various Al models and algorithms to transform scanned input into optimized cutting and printing patterns.

[0077] In some embodiments, the CNC / print system may employ computer vision and Al algorithms to process scanned images, including but not limited to: (i) automatic background removal, (ii) conversion of photographic images to vector-based line drawings, (iii) style transfer to modify artistic characteristics, (iv) image segmentation to separate different elements, and / or (v) enhancement of image contrast and detail. These transformations may be automatically applied or user-selected through a user interface (e.g., a user interface of the CNC / print system, an interface of a network connected processing device such as a computer, phone, tablet, etc., etc.).

[0078] In some embodiments, a CNC / print system includes generative Al capabilities that can: (i) modify or expand scanned artwork, (ii) generate complementary design elements, (iii) create variations of scanned patterns, (iv) suggest alternative layouts or arrangements, and / or (v) automatically generate decorative borders or backgrounds. The CNC / print system may maintain multiple Al models optimized for different artistic styles or design categories.

[0079] In some embodiments, the CNC / print system may implement machine learning algorithms to optimize cutting and printing parameters based on: (i) historical processing results, (ii) material characteristics, (iii) image complexity, (iv) desired output quality, and / or (v) environmental conditions. These algorithms may continuously refine their parameters based on successful outcomes and user feedback.

[0080] In some embodiments, the CNC / print system includes Al-powered material recognition that can: (i) identify material types from camera images, (ii) detect grain patterns or surface characteristics, (iii) recognize and compensate for material defects, (iv) predict optimal processing parameters, and / or (v) warn of potential material compatibility issues. The CNC / printsystem may maintain and update a database of material characteristics and corresponding processing requirements.

[0081] Some embodiments include intelligent job optimization wherein Al algorithms are used to: (i) analyze both printing and cutting requirements to determine optimal processing order, (ii) predict potential quality issues before processing begins, (iii) suggest modifications to achieve better results, and / or (iv) automatically adjust processing parameters based on real-time feedback during fabrication.

[0082] In some embodiments, the CNC / print system may employ neural networks trained to: (i) convert complex images into optimized vector cutting paths, (ii) determine optimal layering of printed and cut elements, (iii) predict material behavior during processing, (iv) identify potential quality issues, and / or (v) suggest alternative approaches when initial attempts are unsuccessful.

[0083] In some embodiments, the CNC / print system implements a hierarchical control architecture wherein a dedicated safety microcontroller unit (MCU) compliant with ISO 13849 Category 3 standards maintains override authority over the main system-on-chip (SoC) processor. This safety-critical architecture ensures that all sensor inputs are double-checked by independent watchdog circuits, providing fault-tolerant operation where any single component failure cannot compromise system safety. The safety MCU continuously monitors critical parameters and can independently initiate protective actions regardless of main processor status.

[0084] In some embodiments, the system employs predictive path planning algorithms that optimize processing efficiency while maintaining safety margins. These algorithms can reduce or minimize laser beam dwell time by dynamically adjusting feed speed when approaching acute corners or complex geometries, preventing excessive heat accumulation that could lead to material damage or combustion. The path planning system may also analyze upcoming geometry and preemptively modulate both laser power and material feed rates to maintain consistent energy delivery per unit area.

[0085] In some embodiments, the CNC / print system incorporates an Al-assisted safety classifier utilizing convolutional neural network (CNN) architectures to evaluate real-time thermal imagery. This intelligent safety system analyzes thermal patterns to identify pre-ignition conditions before visible combustion occurs, enabling preemptive intervention. The CNN model can be trained on extensive datasets of thermal signatures across various materials andprocessing conditions, continuously improving its predictive accuracy through operational learning.

[0086] In some embodiments, the system maintains a comprehensive material profile database containing per-substrate lookup tables that specify permissible power levels, dwell times, and airflow setpoints for different material types. Such a database enables automatic parameter selection based on detected or user-specified materials, ensuring safe and optimal processing parameters are applied. In some embodiments, the material profiles are continuously refined based on processing outcomes and may be updated via cloud connectivity to incorporate learnings from the broader installed base of systems.

[0087] In some embodiments, the system includes natural language processing capabilities allowing users to describe desired modifications or effects in plain language. The system may interpret these descriptions and suggest appropriate transformations or processing parameters to achieve the desired results.

[0088] Some embodiments include collaborative filtering algorithms that can: (i) suggest appropriate materials based on design characteristics, (ii) recommend processing parameters based on similar successful projects, (iii) warn of potential issues based on historical data, and / or (iv) provide design improvement suggestions based on community results.

[0089] In some embodiments, the system may implement Al-powered quality control wherein the CNC / print system: (i) monitors sensors (e.g., cameras) input capturing processing results in real-time, (ii) uses Al models to analyze the results against expected outcomes, (iii) adjusts processing parameters based on the analyzed results to maintain or improve quality, and / or (iv) flag potential issues for user attention before they become critical.

[0090] In some configurations, the CNC / print system 100 includes a safety shutoff feature where, when the laser cutting subassembly is emitting laser light, the CNC / print system 100 is configured to stop emitting laser light from the laser cutting subassembly upon detecting that the top 104 has been opened. In some configurations where the CNC / print system 100 includes a safety shutoff feature, when the laser cutting subassembly is emitting laser light, the CNC / print system 100 is configured to stop emitting laser light from the laser cutting subassembly upon detecting that one or more doors or other openings of a material ingress (e.g., material ingress 106 (FIG. IB, ID), 206 (FIG. 2A), 506a (FIG. 5 A), or 506 (FIG. 5B)) and / ormaterial egress (e g., material egress 226 (FIG. 2A), 526a (FIG. 5 A), or 526 (FIG. 5B)) have been opened.

[0091] As described in further detail herein, some embodiments of the material ingress and / or material egress include resilient elements that operate to block laser light from escaping the interior of the CNC / print system 100 during operation. So, in embodiments where the material ingress and / or egress include both doors and resilient elements, the safety shutoff feature may not cause the CNC / print system 100 to stop emitting laser light from the laser cutting subassembly only upon detecting that the one or more doors or other openings of the material ingress and / or material egress are opened. Instead, in some such embodiments, the safety shutoff feature may be additionally or alternatively configured to detect laser light and / or monitor laser light levels (via one or more sensors positioned near the material ingress and / or material egress) just outside of the material ingress and / or egress, and cause the CNC / print system 100 to stop emitting laser light from the laser cutting subassembly in response to (i) detecting laser light escaping from the material ingress and / or egress, or (ii) detecting laser light above some threshold level escaping form the material ingress and / or egress. In some embodiments, the CNC / print system 100 may be configured with any of the safety shutoff mechanisms shown and described in U.S. App. 17 / 967,850, titled “Enclosure with Selective Wavelength Transmissivity for Computer Numerically Controlled Fabrication,” filed on Oct. 17, 2022, published as U.S. Pub. 2023 / 0185279 on Jun. 15, 2023, and currently pending. The entire contents of U.S. App. 17 / 967,850 are incorporated herein by reference.

[0092] In some embodiments, the CNC / print system implements a comprehensive safety interlock system that monitors the status of printing components and disables laser operation when certain conditions are detected. These safety interlocks help prevent unsafe operation and protect both system components and output quality.

[0093] In some embodiments, the safety interlock system may monitor and respond to ink system status, including but not limited to: (i) low or empty ink conditions in one or more ink cartridges, (ii) missing or improperly installed ink cartridges, (iii) printhead carriage position or status, (iv) ink delivery system pressure, and / or (v) ink waste container capacity. In some implementations, the laser cutting subassembly is disabled when ink cartridges are missing or improperly installed, as the cartridges may form part of the laser light containment system or their absence may create unwanted optical paths for scattered laser light.

[0094] Some embodiments include material feed monitoring interlocks that disable laser operation when detecting conditions including but not limited to: (i) paper jams or material feed errors, (ii) improper material positioning, (iii) material skew beyond acceptable limits, (iv) curled or damaged material edges, and / or (v) material thickness variations outside of specified ranges. These conditions could cause laser light to scatter in unexpected directions or result in improper focusing of the laser beam.

[0095] In some embodiments, the CNC / print system may implement printhead protection interlocks that prevent laser operation when the printhead is in vulnerable positions or conditions, including: (i) when the printhead is in a maintenance position, (ii) during printhead cleaning cycles, (iii) when the printhead temperature is outside acceptable ranges, and / or (iv) when printhead movement is restricted or irregular.

[0096] In some embodiments, the CNC / print system monitors air handling system status and disables laser operation if conditions are detected that could allow smoke or debris to contaminate sensitive components, including: (i) exhaust fan failure or reduced performance, (ii) clogged filters, (iii) improper air pressure differentials, and / or (iv) open access panels that could disrupt designed airflow patterns.

[0097] Some embodiments include sensor monitoring interlocks that disable laser operation when critical sensors are not functioning properly, including but not limited to: (i) temperature sensors, (ii) material detection sensors, (iii) position sensors, (iv) lid closure sensors, (v) air quality sensors, and / or (vi) flame and / or combustion detection sensors.

[0098] In some embodiments, the system includes UV-IR flame detectors mounted at approximately 30-degree angles relative to the material bed, providing optimal viewing angles for detecting both ultraviolet and infrared signatures characteristic of combustion events. These dual-spectrum detectors enable discrimination between actual flames and other heat sources or reflections.

[0099] Some embodiments incorporate a near-infrared (NIR) thermal camera mounted on the gantry system, enabling pixel-wise hotspot mapping across the entire material surface. This thermal imaging capability allows the system to detect localized temperature anomalies, track heat buildup patterns, and identify potential ignition points before visible combustion occurs.The gantry-mounted configuration ensures comprehensive coverage as the thermal camera moves with the processing heads.

[0100] A flame and combustion early-warning network may further include photoionization smoke sensors positioned within the exhaust manifold, providing rapid detection of combustion byproducts at the point where airflow naturally concentrates smoke and vapors. Additionally, some embodiments implement spectro-optical backscatter analysis through the laser path itself, enabling detection of plasma flash events that may indicate material ignition at the laser focal point. This multi-modal sensing approach ensures reliable fire detection across various combustion scenarios while minimizing false alarms.

[0101] Upon detection of hazardous conditions by the early-warning network or other safety sensors, the CNC / print system implements a multi-tiered active mitigation and fail-safe ladder that provides rapid, graduated responses to detected hazards. At the optical level, the system includes a fast blade shutter capable of blocking the laser beam within, for example, 5 milliseconds, positioned inside the laser housing to provide immediate beam termination. In some embodiments, the shutter operates in conjunction with an interlock tree comprising magnetic reed switches on all service doors, ensuring comprehensive monitoring of system access points.

[0102] In some embodiments, a dedicated cut-power relay, controlled by an independent safety microcontroller unit (MCU) individually or as part of a hierarchical control architecture described herein, provides hardware-level power interruption that operates autonomously from the main system controller. This redundant safety architecture ensures fail-safe operation even if the primary control system becomes unresponsive. In some embodiments, the system may, in response to thermal events, deploy targeted fire suppression through gas flooding or micro-mist injection of water or CO2 directly at the focal spot, with total discharge volumes limited to less than, for example, 50 mb to prevent material damage while effectively suppressing combustion.

[0103] The fail-safe ladder may further include automatic material ejection capabilities, wherein auto-eject rollers advance the media, for example, more than 50 mm away from the processing area post-fault, removing potentially compromised material from the danger zone. Multi-modal alerting ensures rapid human intervention when needed, combining visual beacons, audible alarms at, for example, 85 dB to meet industrial safety standards, and push notifications delivered via cloud connectivity to designated personnel. This comprehensive alert system ensures that safety events are promptly communicated regardless of operator location or ambient conditions.

[0104] In embodiments, the CNC / print system may implement graduated responses to different conditions, such as, for example: (i) displaying warnings while allowing operation to continue, (ii) preventing new jobs from starting while allowing current jobs to complete, (iii) pausing operation until conditions are resolved, or (iv) immediate shutdown of laser operations, depending on the severity and safety implications of the detected condition.

[0105] In some embodiments, the system maintains logs of interlock triggers or events and requires administrative authorization to override certain safety interlocks. The system may also implement different interlock behaviors based on user authorization levels, material types being processed, or specific operation modes.

[0106] Some embodiments include self-diagnostic capabilities to verify proper functioning of the interlock systems themselves, including periodic testing of sensors, switches, and control circuits. The CNC / print system may require successful completion of interlock system diagnostics before allowing laser operation to commence. The system’s airflow verification represents a critical safety interlock, employing multiple redundant sensors as described herein.

[0107] In some example embodiments where the top 104 lifts to reveal the bed of the scanner, the scanner can capture image data from a sheet of paper placed within the scanner, where the sheet of paper includes an image of a bird. The image of the bird can then be implemented onto a different piece of material that is fed through the material ingress 106 (or otherwise placed into the interior portion of the housing 102) via one or both of the ink printing subassembly and / or the laser cutting subassembly. For instance, the bird image can be printed via the ink printing subassembly onto a piece of wood and the outline of the bird image can be cut using the laser cutting subassembly. Additionally or alternatively, the bird image can be etched via the laser cutting subassembly onto the piece of wood. Still further, a first portion of the bird image can be etched via the laser cutting subassembly onto the piece of wood, and a second portion of the bird image can be printed via the ink printing subassembly onto the piece of wood. Other variations or combinations of operations of the laser cutting subassembly and ink printing subassembly on the piece of material are possible.

[0108] In some embodiments, the CNC / print system incorporates multiple distance sensing technologies to maintain optimal processing distances for both printing and laseroperations. These distance sensing systems may operate continuously during processing to ensure consistent results across varying material surfaces and conditions.

[0109] In some embodiments, the system may implement multiple types of distance sensors, including but not limited to: (i) optical triangulation sensors, (ii) time-of-flight sensors, (iii) confocal chromatic sensors, (iv) laser displacement sensors, and / or (v) structured light sensors. Different sensor types may be selected based on material properties, required precision, and operating conditions. In some embodiments, multiple sensor types work in conjunction to provide redundancy and enhanced accuracy.

[0110] Some embodiments include an array of distance sensors positioned to: (i) create detailed surface topology maps of materials being processed, (ii) detect warping or irregularities in material surface, (iii) identify sudden changes in material thickness, and / or (iv) monitor material positioning during processing. The CNC / print system may, for example, maintain continuous surface maps updated in real-time during processing.

[0111] In some embodiments, the CNC / print system may implement dynamic focus adjustment wherein: (i) distance measurements are used to automatically adjust laser focus parameters, (ii) printhead height is continuously optimized for different material thicknesses, (iii) processing parameters are modified based on detected surface variations, and / or (iv) the system compensates for material movement or deformation during processing.

[0112] In some embodiments, the distance sensing system includes: (i) high-speed sampling capabilities for real-time adjustment during motion, (ii) sub-micron measurement precision for critical applications, (iii) ability to measure multiple surface types including highly reflective or transparent materials, and / or (iv) compensation for environmental factors such as temperature and humidity.

[0113] In some embodiments, the system may implement predictive surface tracking wherein: (i) surface measurements are used to predict upcoming variations, (ii) processing parameters are pre-adjusted based on predicted changes, (iii) motion paths are optimized to maintain consistent processing distances, and / or (iv) the system learns from historical data to improve prediction accuracy.

[0114] Some embodiments include intelligent error handling wherein: (i) processing is automatically paused if distance variations exceed specified thresholds, (ii) the system attemptsautomatic correction of detected issues, (iii) users are alerted to conditions requiring intervention, and / or (iv) processing parameters are automatically adjusted to accommodate minor variations.

[0115] In some embodiments, the CNC / print system may implement zone-based distance monitoring wherein: (i) different distance thresholds are maintained for different processing areas, (ii) multiple sensor inputs are combined to create comprehensive surface maps, (iii) separate monitoring for printing and cutting operations, and / or (iv) specialized monitoring for critical features or areas.

[0116] In some embodiments, the system includes calibration capabilities wherein: (i) distance sensors are automatically calibrated using reference surfaces, (ii) cross-validation between different sensor types is performed, (iii) compensation for material-specific properties is performed, and / or (iv) periodic verification of sensor accuracy is performed during operation.

[0117] In some embodiments, the CNC / print system may maintain detailed logs of distance measurements enabling: (i) quality control verification, (ii) process optimization, (iii) identification of problematic material conditions, and / or (iv) validation of processing consistency across multiple jobs.

[0118] In some embodiments, the CNC / print system implements comprehensive autofocus capabilities for both laser cutting and printing operations. The autofocus system may utilize multiple focusing methods and technologies to maintain optimal focus under varying conditions and for different materials.

[0119] In some embodiments, the system may implement various autofocus methods including but not limited to: (i) contrast detection focusing, where the system analyzes image sharpness across multiple focal positions, (ii) phase detection focusing using split-image comparison, (iii) laser triangulation focusing that measures reflected laser light patterns, and / or (iv) multi-point focusing that maintains focus across irregular surfaces. In embodiments, different focusing methods may be automatically selected based on material properties and processing requirements.

[0120] Some embodiments include dynamic focus adjustment capabilities wherein: (i) focus parameters are continuously updated during processing, (ii) predictive focus adjustment is used to anticipate surface variations, (iii) separate focus optimization is implemented for printing and cutting operations, and / or (iv) compensation for thermal expansion or material deformationis performed during processing. The system may, for example, maintain focus maps that are updated in real-time as processing progresses.

[0121] In some embodiments, the CNC / print system may implement intelligent focus zone management wherein: (i) different areas of the material maintain independent focus parameters, (ii) focus transitions are smoothly managed between zones, (iii) critical features receive enhanced focus monitoring, and / or (iv) focus parameters are optimized based on local material characteristics.

[0122] In some implementations, the autofocus system includes multi-layer focusing capabilities for: (i) maintaining separate focus parameters for different material layers, (ii) optimizing focus for both surface printing and through-cutting operations, (iii) managing focus requirements for materials of varying transparency, and / or (iv) maintaining focus consistency across material transitions.

[0123] In some embodiments, the system may implement focus calibration procedures wherein: (i) focus parameters are automatically calibrated using reference materials, (ii) focus accuracy is verified through test patterns, (iii) environmental factors are compensated for through calibration adjustments, and / or (iv) focus parameters are refined based on processing results.

[0124] Some embodiments include focus quality monitoring, including: (i) real-time analysis of focus accuracy during processing, (ii) automatic correction of detected focus issues, (iii) logging of focus-related quality metrics, and / or (iv) alerts when focus quality falls below specified thresholds.

[0125] In some embodiments, the CNC / print system may implement material-specific focus optimization wherein: (i) focus parameters are automatically adjusted based on material properties, (ii) focus strategies are selected based on material surface characteristics, (iii) compensation for material-specific optical properties, and / or (iv) maintenance of focus parameter databases for different materials.

[0126] In some embodiments, the system includes hybrid focusing strategies that combine: (i) fixed focus parameters for uniform materials, (ii) dynamic focus adjustment for irregular surfaces, (iii) multi-point focus for complex geometries, and / or (iv) adaptive focus adjustment based on processing requirements.

[0127] In some embodiments, the system may maintain detailed focus performance logs enabling: (i) analysis of focus accuracy over time, (ii) correlation of focus parameters withprocessing quality, (iii) optimization of focus strategies for different materials and conditions, and / or (iv) predictive maintenance of focus-related components.

[0128] FIG. IB shows an overhead cutaway view of the example CNC / print system 100 for laser fabrication and ink printing shown in FIG. 1 A according to some embodiments.

[0129] The overview cutaway view in FIG. IB reveals an interior portion 108 of the housing 102. In operation, while material (or at least a region or other portion of the material) is positioned within the interior portion 108 of the housing 102 of the CNC / print system 100, the CNC / print system 100 is configured to (i) apply laser power to the region of material positioned within the interior portion 108 of the housing 102 via the laser cutting subassembly (not shown in FIG. IB) and (ii) applying ink to the region of material positioned within the interior portion 108 of the housing 102 via the ink printing subassembly (not shown in FIG. IB).

[0130] Regardless of whether the CNC / print system 100 processes the material with one or both of the laser cutting subassembly or the ink printing subassembly, the material (or at least a region or other portion of the material) in some embodiments is fed into the interior portion 108 of the housing 102 via the material ingress 106. In operation, the material feeding subassembly 110 is configured to move the material through the interior portion 108 of the housing 102 when the CNC / print system 100 is processing the material via the laser cutting subassembly and / or the ink printing subassembly.

[0131] In some embodiments, the CNC / print system implements various methods for retaining material connectivity during cutting operations to prevent premature separation of cut pieces while maintaining precise alignment. These retention methods may be automatically selected and implemented based on factors including but not limited to: (i) material type and thickness, (ii) cut pattern geometry, (iii) size of pieces being cut, and / or (iv) intended end-use of the finished product.

[0132] In some embodiments, the CNC / print system may implement tab retention, wherein the laser cutting subassembly is configured to leave small uncut sections ("tabs") at strategic locations along cut lines. In some implementations, the system automatically calculates optimal tab placement based on: (i) the size and weight of pieces being cut, (ii) material properties, (iii) cutting pattern geometry, and / or (iv) intended handling requirements. In some embodiments, tab dimensions may be automatically adjusted based on material properties, with typical dimensions ranging from, for example, 0.2mm to 2mm in length. Some embodimentsallow user specification of tab placement and dimensions through a design interface that may be on the CNC / print system or on a network connected processing device.

[0133] Some embodiments implement partial-depth cutting wherein the laser cutting subassembly is configured to cut partially through the material thickness, leaving a thin connected layer at the bottom of the material. In some embodiments, the CNC / print system may automatically calculate optimal cutting depth based on material properties and thickness, typically leaving, for example, 5-20% of material thickness intact. In some embodiments, the partial-depth cut pattern includes periodic full-depth sections to facilitate clean separation while maintaining overall piece alignment.

[0134] In some embodiments, the CNC / print system may include a mechanical wiper subassembly configured to separate cut pieces from the surrounding material. In some implementations, the wiper subassembly includes: (i) a flexible blade element that moves across the material surface, (ii) an actuator system controlling blade movement and pressure, (iii) sensors detecting successful separation, and / or (iv) a collection system for separated pieces. The wiper subassembly may be, for example, programmed to operate at specific intervals or after completion of defined cutting regions.

[0135] In some embodiments, the CNC / print system may implement a vacuum-assisted separation wherein the material platform includes: (i) a matrix of vacuum channels or holes, (ii) independently controlled vacuum zones, (iii) variable vacuum pressure control, and / or (iv) sensors monitoring vacuum effectiveness. The CNC / print system may, for example, dynamically adjust vacuum pressure based on material properties and cutting progress, with higher vacuum pressure applied to areas where pieces have been cut and require separation.

[0136] In some embodiments, the CNC / print system includes a combination of retention methods that work together. For example: (i) tabs may be used in conjunction with partial-depth cutting for larger pieces, (ii) vacuum separation may be combined with wiper action for smaller pieces, or (iii) different retention methods may be used on different areas of the same project based on local geometric requirements. Other examples exist.

[0137] In some embodiments, the CNC / print system may implement intelligent piece removal sequencing, wherein: (i) cut patterns are analyzed to determine optimal cutting order, (ii) retention methods are applied differently to interior and exterior cuts, (iii) multiple passeswith different retention methods are used for complex patterns, and / or (iv) the system provides instructions to the user for manual removal of pieces in a specific order.

[0138] In some embodiments the CNC / print system includes detection and adjustment capabilities wherein: (i) sensors (e.g., internal cameras, etc.) monitor the effectiveness of retention methods, (ii) retention parameters are adjusted based on detected results, (iii) alternative retention methods are (e.g., automatically) implemented if initial methods prove ineffective, and / or (iv) the system maintains a database of successful retention parameters for different materials and patterns.

[0139] Processing material with the laser cutting subassembly tends to create substantial effluence as laser energy is applied to the surface of the material to cut through the material and / or etch / engrave the surface of the material. For example, in some instances, executing a fabrication job that includes some type of laser fabrication step (e.g., cutting, etching, engraving, scoring, etc. with the laser) via the laser cutting subassembly generates effluence (e.g., debris from the laser cutting / etching process) which can, in some scenarios, build up on the surface of interior components of the CNC / print system 100.

[0140] Effluent buildup on the internal components of the CNC / print system 100 is undesirable. For example, buildup on the internal moving parts (e.g., gantry subassemblies that facilitate movement of one or both of the laser cutting subassembly and / or the ink printing subassembly) can impede smooth movement of those internal moving parts, which can affect the speed and precision of their movement, thereby causing reduced quality fabrication results. Similarly, effluent buildup on lenses of internal cameras can result in poor quality images. Effluent buildup on focusing elements of the laser cutting subassembly can affect the ability of those focusing elements to focus laser power onto the surface of material processed by the CNC / print system 100 effectively.

[0141] To avoid effluent buildup, or at least reduce the rate of effluent buildup on internal components, some embodiments of the CNC / print system 100 include an integrated debris removal system. In some examples, the debris removal system includes an exhaust system 112 within the housing 102 of the CNC / print system 100. The exhaust system 112 includes a plurality of fans 114a, 114b, and 114c configured to pull air containing debris out of the interior portion 108 the housing 102 via a plurality of exhaust ports 116a, 116b, and 116c. In operation, fan 114a pulls air (including air containing effluent and other debris) out of theinterior portion 108 of the housing 102 via exhaust port 116a, fan 114b pulls air (including air containing effluent and other debris) out of the interior portion 108 of the housing 102 via exhaust port 116b, and fan 114c pulls air (including air containing effluent and other debris) out of the interior portion 108 of the housing 102 via exhaust port 116c.

[0142] In some embodiments, the CNC / print system includes multiple stages of air filtration, including: (i) pre-filters for large particles, (ii) HEPA filtration for fine particles, (iii) activated carbon filters for vapor absorption, (iv) electrostatic precipitation for submicron particles, and / or (v) specialized filters for specific materials being processed. Filter status monitoring may automatically alert when replacement is needed.

[0143] In some embodiments, the CNC / print system may implement dynamic airflow adjustment wherein: (i) air handling parameters are modified based on the type of material being processed, (ii) extraction rates are adjusted based on detected contamination levels, (iii) airflow patterns are modified during different phases of operation, and / or (iv) emergency high-flow modes are activated if contamination is detected near sensitive components.

[0144] In some embodiments, the CNC / print system may include air quality monitoring systems that: (i) measure particle concentrations at multiple points within the system, (ii) detect specific vapors or compounds that could damage components, (iii) monitor temperature and humidity in different zones, and / or (iv) trigger automated responses to maintain air quality within specified parameters. These actions may be done continuously, periodically, and / or based on events (e.g., user input, new print job established, print job completed, etc.) detected by the system.

[0145] Some embodiments with a gantry subassembly (e.g., the gantry subassemblies shown in FIGS. 3 A and 3B) are configured to remove effluent from one or more rails of the gantry subassembly. For example, in some embodiments, the laser cutting head 320 is configured to move back and forth along one or more rails of the gantry subassembly via a carriage. The carriage includes openings that enable the carriage to move along the rail(s) of the gantry. The openings include a tooth and groove configuration that is arranged to clean effluent off of the rail(s) of the gantry as the carriage moves the laser cutting head back and forth along the gantry rail(s). Examples of carriages having openings with tooth and groove configurations that can be used with the laser cutting head implementations employed by the embodiments disclosed herein are shown and described with reference to FIGS. 3C-F in U.S. App. 18 / 772,152,titled “Systems and Methods for Laser Fabrication,” fded on Jul. 13, 2024, and currently pending; the entire contents of U.S. App. 18 / 772,152 are incorporated herein by reference.

[0146] In some configurations, the exhaust system 112 additionally includes one or more filters arranged to capture debris and effluent from the air before expelling the air via the exhaust ports 116a, 116b, and 116c. In some embodiments, each of the exhaust ports 116a, 116b, and 116c has one or more corresponding air filters. Some embodiments include one or more air filters that are common to all of the exhaust ports 116a, 116b, and 116c.

[0147] Beyond the primary exhaust system 112, the CNC / print system may implement supplemental cooling and air-handling schemes as described in further detail herein, including carriage-mounted micro-blowers, positive-pressure plenum beds, and inert-gas purge capabilities. These supplemental systems work in conjunction with the exhaust system 112 to maintain optimal processing conditions while preventing cross-contamination between laser cutting effluent and ink printing operations. The system employs redundant airflow verification sensors to ensure that both the primary exhaust system 112 and any supplemental cooling systems maintain proper operation before enabling laser cutting operations.

[0148] In some embodiments, the CNC / print system implements a comprehensive crosscontamination prevention system designed to protect printed surfaces from debris, residue, and other byproducts generated during laser cutting operations. A comprehensive crosscontamination prevention system is important to maintain print quality when combining printing and cutting operations in a single device.

[0149] In some embodiments, the CNC / print system may implement a dynamic debris shield subsystem comprising: (i) a moveable protective shield that travels with the laser cutting head, (ii) actuators controlling shield position and angle, (iii) sensors monitoring shield effectiveness, and / or (iv) automated cleaning mechanisms for the shield itself. The shield may, for example, be automatically deployed during cutting operations and retracted during printing operations, with position and movement coordinated with both laser cutting head and printhead movements to prevent interference while maintaining protection.

[0150] Some embodiments include an electrostatic control system that: (i) applies controlled electrical charges to different zones of the material surface, (ii) actively repels debris particles from printed areas, (iii) attracts debris toward collection areas, and / or (iv) neutralizes static charges that could cause debris accumulation. The system may, for example, includemultiple charge emitters and sensors positioned strategically throughout the processing area to maintain optimal charge distribution patterns.

[0151] In some embodiments, the CNC / print system may implement a temporary protective film application system wherein: (i) a thin protective film is automatically applied over printed areas before cutting operations begin, (ii) the film is removed after cutting operations are complete, (iii) film application and removal is coordinated with other processing steps, and / or (iv) film properties are selected based on material characteristics and processing requirements. In some embodiments, the protective film may be applied selectively only to areas at risk of contamination.

[0152] Some embodiments include a multi-zone processing area wherein: (i) physical barriers separate printing and cutting zones, (ii) automated material handling systems transfer materials between zones, (iii) air handling systems maintain separate environments for each zone, and / or (iv) decontamination procedures are automatically performed during zone transitions. Such a system may dynamically adjust zone configurations based on job requirements and contamination risks.

[0153] In some embodiments, the CNC / print system may implement intelligent particle control wherein: (i) real-time particle monitoring sensors detect contamination risks, (ii) processing parameters are automatically adjusted to minimize debris generation, (iii) air handling patterns are modified to direct particles away from sensitive areas, and / or (iv) emergency contamination prevention measures are triggered when threshold particle levels are detected.

[0154] Some embodiments include a surface cleaning subsystem that: (i) automatically cleans material surfaces between processing steps, (ii) implements different cleaning methods based on contamination type and material properties, (iii) verifies cleaning effectiveness through optical inspection, and / or (iv) maintains cleaning history logs for quality control purposes. The cleaning subsystem may, for example, use various methods including air jets, brush mechanisms, and / or specialized cleaning solutions.

[0155] In some embodiments, the CNC / print system may implement predictive contamination modeling wherein: (i) cut patterns are analyzed to predict likely contamination patterns, (ii) protection strategies are optimized based on predicted risks, (iii) processing sequences are modified to minimize contamination potential, and / or (iv) protection systems are pre-positioned based on anticipated contamination patterns.

[0156] In some embodiments, the system includes mated al -specific contamination prevention strategies wherein: (i) different protection methods are selected based on material properties, (ii) cutting parameters are optimized to minimize debris generation for specific materials, (iii) cleaning protocols are customized for different material types, and / or (iv) the system maintains a database of effective protection strategies for different materials and processes.

[0157] In some embodiments, the CNC / print system may maintain detailed contamination prevention logs enabling: (i) analysis of protection system effectiveness, (ii) optimization of prevention strategies, (iii) identification of systematic contamination risks, and / or (iv) validation of quality control measures. These logs may be used to continuously refine and improve contamination prevention strategies.

[0158] In some embodiments, the CNC / print system implements an integrated maintenance system that services both laser and printing components during automated maintenance cycles. The system leverages existing printer maintenance mechanisms while adding specialized capabilities for laser optics care. The maintenance system may include, for example, a combined service station that provides: (i) traditional printhead wiping, capping, and priming functions for the ink system, (ii) an optical cleaning system for laser components, and (iii) shared cleaning verification sensors. During maintenance cycles, for example, both the printhead and laser head dock at the service station sequentially or simultaneously depending on configuration.

[0159] Some embodiments include an optical cleaning system comprising: (i) a pressurized air nozzle array that delivers focused air bursts to remove debris from laser optics,(ii) an electrostatically-charged cleaning brush that attracts particles away from optical surfaces,(iii) a specialized wiping element with optical-grade cleaning surfaces, and / or (iv) sensors that detect successful cleaning completion. The system may, for example, maintain the cleaning elements in a sealed environment when not in use to prevent contamination.

[0160] In some embodiments, the CNC / print system may implement intelligent maintenance scheduling wherein: (i) maintenance cycles are triggered based on operating time, detected performance degradation, or environmental conditions, (ii) different types of cleaning operations are performed based on detected issues, (iii) maintenance operations are sequenced tominimize total downtime, and / or (iv) cleaning cycles are scheduled between jobs or during natural processing pauses.

[0161] Some embodiments include a verification system that: (i) performs test patterns using both printing and laser functions, (ii) analyzes results using on-board cameras to detect quality issues, (iii) repeats cleaning cycles if necessary, and / or (iv) alerts users when manual intervention is required. The system may, for example, maintain logs of maintenance effectiveness to optimize future cleaning cycles.

[0162] In some embodiments, the maintenance system may employ shared cleaning resources including: (i) a common vacuum system that removes debris from both printing and laser cleaning operations, (ii) a unified waste collection system, (iii) shared cleaning solution delivery for applicable components, and / or (iv) common air handling for drying and particle removal.

[0163] In some embodiments, the system includes specialized maintenance patterns wherein: (i) the laser performs low-power cleaning passes to loosen debris, (ii) the printhead deposits cleaning solution in specific patterns, (iii) coordinated movement of both heads creates enhanced cleaning action, and / or (iv) specific maintenance sequences are designed for different types of contamination.

[0164] In some embodiments, the CNC / print system may implement predictive maintenance wherein: (i) sensors monitor key indicators of system cleanliness, (ii) cleaning cycles are initiated before visible quality degradation occurs, (iii) maintenance intensity is adjusted based on usage patterns and environmental conditions, and / or (iv) the system learns from historical maintenance effectiveness data.

[0165] Some embodiments include emergency cleaning protocols that: (i) can be triggered during job processing if contamination is detected, (ii) implement rapid cleaning procedures to minimize job interruption, (iii) adjust processing parameters to reduce contamination until full maintenance can be performed, and / or (iv) provide users with real-time status updates and estimated completion times.

[0166] In some embodiments, the system may maintain separate maintenance schedules and procedures for different operating environments, such as: (i) more frequent cleaning cycles in dusty environments, (ii) adjusted procedures for high-humidity conditions, (iii) specializedcleaning for different material types, and / or (iv) modified maintenance timing based on usage patterns.

[0167] In some embodiments, the CNC / print system implements a sophisticated air management system specifically designed to protect sensitive components from laser cutting byproducts while maintaining optimal operating conditions for both laser and printing operations. The air management system may include precisely engineered airflow paths and multiple air handling zones to prevent cross-contamination between cutting and printing areas.

[0168] In some embodiments, the CNC / print system may implement a positive pressure zone around the ink printing subassembly wherein: (i) filtered air is actively supplied to create an overpressure barrier, (ii) airflow patterns direct contaminated air away from sensitive printing components, (iii) pressure sensors monitor zone integrity, and / or (iv) airflow rates are automatically adjusted based on real-time air quality measurements. This positive pressure zone helps prevent smoke, vapors, and particles from the laser cutting process from reaching the printhead or other sensitive printing components.

[0169] In some embodiments, the CNC / print system may include multiple air handling zones with independent control systems, including but not limited to: (i) a high-flow extraction zone around the laser cutting area, (ii) a clean air supply zone around printing components, (iii) transition zones between cutting and printing areas, and / or (iv) filtered air supply zones for optical components. Each zone may have independent air pressure monitoring and control.

[0170] In some embodiments, the CNC / print system may implement laminar airflow patterns designed to: (i) maintain stable air currents during operation, (ii) prevent turbulent mixing of clean and contaminated air, (iii) guide particulates and vapors directly to extraction points, and / or (iv) maintain consistent environmental conditions around sensitive components. Computational fluid dynamics modeling may be used to design and / or improve these airflow patterns. In some embodiments, modeling may be done based on the type of CNC / print job and / or dynamically based on the current sensor readings.

[0171] In some embodiments, the CNC / print system may implement thermal management through the air handling system, including: (i) temperature-controlled air supply to sensitive components, (ii) cooling air circuits for laser components, (iii) temperature gradient management between different zones, and / or (iv) humidity control for optimal printing conditions.

[0172] In some implementations, the CNC / print system may include automated cleaning cycles wherein: (i) high-velocity air purges are used to clean accumulated debris, (ii) specialized cleaning cycles are triggered based on accumulated operating time or detected contamination levels, (iii) different cleaning protocols are implemented for different zones, and / or (iv) system operation is suspended until cleaning cycles complete.

[0173] In some embodiments, the CNC / print system may maintain detailed logs of air quality parameters and system responses, enabling: (i) predictive maintenance scheduling, (ii) optimization of air handling parameters, (iii) early detection of developing issues, and / or (iv) validation of system performance over time.

[0174] In some embodiments, the CNC / print system implements various cooling and airhandling schemes based on a general principle of maintaining laminar, coaxial flow enveloping the laser focal point while isolating ink mist from critical optical components. In some embodiments, the system includes an integrated micro-blower, either radial or axial configuration, mounted directly on the carriage to provide localized airflow control. Alternative embodiments may employ a remote compressor connected via flexible hose with quick-release pneumatic fittings, enabling rapid maintenance and reconfiguration. Some embodiments implement a venturi assist mechanism driven by the high-pressure ink system waste line, utilizing existing system pressure to generate supplemental airflow without additional power consumption.

[0175] In some embodiments, the system includes a positive-pressure plenum bed that forces airflow upward through the substrate, providing symmetric cooling from both sides of the material during processing. For specialized applications, the system may include an inert-gas purge capability using nitrogen (N?) or carbon dioxide (CO2), with gas selection determined by job profile parameters to optimize cutting quality and prevent oxidation or combustion of sensitive materials.

[0176] In some embodiments, the CNC / print system employs multiple redundant airflow verification sensors to ensure safe operation. These sensors include: (i) MEMS differentialpressure transducers positioned at duct inlet and outlet locations to verify pressure differential meets or exceeds setpoint values, providing single redundancy; (ii) thermal mass-flow sensors (hot-wire type) at nozzle exits measuring flow rate in CFM with double redundancy; (iii) Halleffect tachometers on blower motor rear sections monitoring RPM without redundancy; (iv)piezo flap microphones positioned inside ducts to detect acoustic signatures of proper airflow with single redundancy; and / or (v) solid-state anemometers mounted on duct walls measuring velocity vectors with single redundancy. The system implements safety logic whereby laser operation is enabled only when two or more independent sensor metrics concur, ensuring failsafe operation even if a single sensor fails or provides erroneous readings.

[0177] FIG. 1C shows a rear view of the example CNC / print system 100 for laser fabrication and ink printing shown in FIG. 1 A according to some embodiments. The rear view of FIG. 1C shows (i) the exhaust ports 116a, 116b, and 116c arranged to expel air (e.g., air containing debris / effluent) from inside of the housing 102 and (ii) the top 104 that lifts to reveal the interior portion of the housing 102 and / or the scanner configured to capture image data corresponding to items placed within the scanner (depending on the configuration).

[0178] FIG. ID shows a front view of the example CNC / print system 100 for laser fabrication and ink printing shown in FIG. 1A according to some embodiments. The front view of FIG ID shows (i) the top 104 that lifts to reveal the interior portion of the housing 102 and / or the scanner (e.g., configured to capture image data corresponding to items placed within the scanner) (depending on the configuration), and (ii) the material ingress 106 via which material to be processed by the CNC / print system 100 can be fed into the interior portion of the housing 102 for processing by one or both of a laser cutting subassembly and / or an ink printing subassembly contained within the housing 102.

[0179] FIG. 2A shows a side cutaway view of an example CNC / print system 200 for laser fabrication and ink printing according to some embodiments. In some embodiments, CNC / print system 200 is the same as or substantially the same as CNC / print system 100 shown and described with reference to FIGS. 1A-D.

[0180] Similar to CNC / print system 100, CNC / print system 200 includes a housing 202, a lid 204, a material ingress 206, a material feeding subassembly 210, and an exhaust system 212 with one or more exhaust fans 214 and one or more exhaust ports 216. The housing 202, lid 204, material ingress 206, material feeding subassembly 210, and exhaust system 212 with exhaust fan(s) 214 and exhaust port(s) 216 are the same as or substantially the same as the housing 102, lid 104, material ingress 106, material feeding subassembly 110, and exhaust system 112 with exhaust fans 114a-c and exhaust ports 116a-c shown and described with reference to FIGS. 1A- D.

[0181] The cutaway view of FIG. 2 A shows a side view of the interior portion 208 of the housing 202. Like CNC / print system 100, CNC / print system 200 also includes a laser cutting subassembly and an ink printing subassembly.

[0182] The laser cutting subassembly includes a laser cutting head 220 that is arranged to apply laser power to material 230 positioned within the interior portion 208 of the housing 202. Examples of material 230 than can be processed by the laser cutting head 220 include wood, paper, acrylic, glass, cardboard, leather, metal, or any of the material capable of being processed (e.g., cut, etched, engraved, scored, etc.) by a laser. More specifically, the CNC / print system is configured to process a wide variety of printable and cuttable media. Suitable materials include, but are not limited to, paper ranging from 20 to 400 gsm (grams per square meter), photopaper, sticker paper, labels, cardstock, and corrugated materials. The system can also process various fabrics including both natural and synthetic materials, thin wood veneers having thickness less than 2 mm, and polymer films such as polyethylene (PE), polyethylene terephthalate (PET), and polyvinyl chloride (PVC). Additional processable materials include leather, sheet foam, edible wafer paper for food-safe applications, and metallized laminates. In some embodiments, the CNC / print system includes an auxiliary fluid channel configured to apply an optional flameretardant pre-coat spray to materials prior to laser processing, thereby enhancing safety and reducing the risk of combustion during laser cutting operations on flammable substrates.

[0183] In some embodiments, the material 230 includes material that includes a coating on the surface, where the coating is prepared to receive ink dispensed via the ink printing head 222. For example, ink that is applied directly to metal may smudge. So to avoid smudging, the metal may be coated with a film or other coating upon which the ink printing head 222 can deposit ink with less chance of smudging (as compared to depositing the ink directly on the surface of the metal.

[0184] In some embodiments, the material 230 includes material that includes a coating on the surface that makes the material more resistant to heat and / or soot than the material would otherwise be. For example, certain woods may bum easily, which can present challenges when using the laser cutting head 220 to process the material. To execute better quality cuts on such materials without excess burning or charring around the cuts, some materials include a heat and / or soot resistant film or other coating on the surface so that the laser cutting head 220 can create cleaner, more accurate cuts on the surface of the material.

[0185] In some embodiments, the material 230 may include material that includes a coating that makes it easier to wipe away soot or other residue from the surface of the material after processing the material with the laser cutting head 220.

[0186] In still further embodiments, the material 230 may include top coverings and / or backings that facilitate processing. For example, the material may have a top covering and / or a backing that can be removed after processing the material with the laser cutting head 220.

[0187] In still further embodiments, the material 230 may include top coverings and / or backings that facilitate processing. For example, the material may have a top covering and / or a backing that can be removed after processing the material with the laser cutting head 220.

[0188] In some embodiments, the material 230 may have a backing that does not interact with the laser emitted via the laser cutting head 220, thereby enabling “kiss cutting” of material via the laser cutting head 220. For example, embodiments when the laser is a blue laser (400 nm -500 nm), a clear backsheet can be used with the material 230. The blue laser will not penetrate the clear backsheet. The clear backsheet can be attached to various materials either manually by the user or materials may be configured with such a backsheet at the time of material manufacture.

[0189] The laser cutting head 220 may be configured to apply laser power to material 230 from any type of laser now known or later developed that is suitable for performing laser fabrication procedures, including but not limited to laser cutting, laser etching, laser engraving, and / or laser scoring any of the above-mentioned types of materials.

[0190] In some embodiments, the CNC / print system employs predictive path planning algorithms that analyze the cutting pattern geometry in advance of cutting operations. When the laser cutting head 220 approaches acute corners, tight curves, or intricate details, these algorithms dynamically adjust the feed speed of the material feeding subassembly 210 and / or the power output of the laser to minimize beam dwell time, preventing excessive heat accumulation that could cause unwanted burning, material warping, or compromised cut quality.

[0191] For ease of explanation, the term “laser cutting” is sometimes used herein to refer to any laser fabrication process, including but not limited to the aforementioned laser cutting, laser etching, laser engraving, and laser scoring processes.

[0192] For example, in some embodiments, the laser cutting head 220 includes one or more non-pumped solid state laser diodes configured to apply laser power to material 230positioned within the housing 202, e.g., blue wavelength lasers (-400-500 nm lasers) or any other type of solid state laser suitable for laser fabrication of materials such as material 230.

[0193] In other example embodiments, the laser cutting head 220 is configured to apply laser power to material 230 positioned within the housing 202 from a carbon dioxide (CO2) laser. In some embodiments where the laser cutting head 220 is configured to apply laser power from a CO2 laser, the laser cutting head 220 may not include the actual CO2 laser. Instead, the CO2 laser may be separate from the laser cutting head 220, and a system of fiber optics and / or free-space optics may be used to route the beam generated by the CO2 laser from the CO2 laser to the laser cutting head 220 for application to the material 230. For example, the Glowforge ® PRO laser cutter includes a CO2 laser that is separate from the laser cutting head. The Glowforge PRO has a system of fiber optics and free-space optics that route the laser beam generated by the CO2 laser from the CO2 laser to the laser cutting head for application to materials processed by the Glowforge PRO system.

[0194] In other example embodiments, the laser cutting head 220 is configured to apply laser power from any suitable laser, including but not limited to (i) CO2 lasers, (ii) Quantum Cascade Lasers (QCL), (iii) semiconductor lasers, (iv) fiber lasers, (v) continuous lasers, (vi) pulsed lasers at various pulse frequencies, or (v) any other type or configuration of laser now known or later developed that would be suitable for fabrication the type of materials described herein.

[0195] In some examples, the laser cutting head 220 is the same as or similar to as any of the laser cutting head embodiments shown and described in U.S. App. 18 / 772,152, titled “Systems and Methods for Laser Fabrication,” filed on Jul. 13, 2024, and currently pending, including but not limited to the embodiments shown and described with reference to Figures 3A, 3B, and 5 of U.S. App. 18 / 772,152. The entire contents of U.S. App. 18 / 772,152 are incorporated herein by reference.

[0196] In some embodiments, the ink printing subassembly is configured to apply ink to the surface of the material 230 via an inkjet printing process. In such embodiments, the ink printing subassembly includes an ink printing head 222 that includes one or more nozzles arranged to apply ink to a region of the material 230 positioned within the interior portion 208 of the housing. Some embodiments that employ inkjet printing procedures may additionally include one or more UV lights positioned with the CNC / print system 200 and configured toapply UV light to ink applied to the surface of the material 230 to cure the ink on the surface of the material 230. In some embodiments, laser energy emitted from the cutting head 220 can instead be used to cure the ink that ink printing head 222 has applied to the surface of the material 230.

[0197] In some embodiments, the ink printing subassembly is additionally or alternatively configured to apply ink (in the form of toner) to the surface of the material 230 via a laser printing process. The laser printing process implemented by the ink printing subassembly in such embodiments is different than the laser fabrication process implemented by the laser cutting subassembly despite both processes (and subassemblies) implementing laser technology.

[0198] In some embodiments, the CNC / print system includes one or more protective coating subsystems configured to apply and cure protective finishes to processed materials.These protective coatings may be applied before printing, between printing and cutting operations, and / or as a final finishing step to enhance durability, appearance, and material properties.

[0199] In some embodiments, the protective coating subsystem may include: (i) one or more spray nozzles configured to apply protective coatings, (ii) UV curing lights positioned to cure applied coatings, (iii) sensors monitoring coating coverage and curing status, (iv) a collection system for overspray, and / or (v) air handling components to manage coating vapors. In some embodiments, the spray nozzles are mounted on the same gantry system used for printing and cutting operations, allowing precise control of coating application.

[0200] In some embodiments, the CNC / print system may apply UV-curable protective coatings that may provide various properties including but not limited to: (i) scratch resistance, (ii) water resistance, (iii) UV protection, (iv) enhanced color vibrancy, (v) specific surface textures, and / or (vi) varying levels of gloss or matte finish. The CNC / print system may, for example, maintain multiple coating formulations optimized for different materials and applications.

[0201] In some embodiments, the CNC / print system may include UV-curable inks in the ink printing subsystem, wherein: (i) UV curing lights are integrated with the print head assembly, (ii) curing occurs immediately after ink deposition, (iii) different curing intensities or wavelengths are used for different ink formulations, and / or (iv) curing parameters are automatically adjusted based on material properties and environmental conditions.

[0202] In some embodiments, the protective coating subsystem includes multiple coating stages allowing for: (i) primer or preparation coatings, (ii) intermediate protective layers between printing and cutting operations, (iii) final protective overcoats, and / or (iv) different coating formulations applied to different regions of the material. The CNC / print system may, for example, automatically sequence these coating operations with printing and cutting steps.

[0203] In some embodiments, the CNC / print system may implement intelligent coating control wherein: (i) coating thickness is automatically adjusted based on material properties and intended use, (ii) multiple coating layers are applied with varying cure times between layers, (iii) coating patterns are modified based on cut patterns to prevent edge accumulation, and / or (iv) coating parameters are adjusted based on environmental conditions such as temperature and humidity.

[0204] Some embodiments include coating quality monitoring wherein: (i) sensors detect coating coverage and uniformity, (ii) UV curing effectiveness is monitored in real-time, (iii) surface quality is evaluated after curing, and / or (iv) additional coating layers are automatically applied to areas with insufficient coverage.

[0205] In some embodiments, the CNC / print system may implement selective coating capabilities wherein: (i) protective coatings are applied only to specific regions of the material, (ii) different coating formulations are applied to different regions, (iii) coating patterns are synchronized with printed and cut patterns, and / or (iv) masking is automatically applied to protect regions that should not receive coating.

[0206] In some embodiments, the CNC / print system includes coating parameter optimization wherein: (i) coating formulations are selected based on material properties and intended use, (ii) application parameters are adjusted based on environmental conditions, (iii) curing parameters are optimized for different coating types, and / or (iv) the system maintains a database of successful coating parameters for different materials and applications. Some embodiments may also include a substrate pre-conditioning station configured to prepare materials before processing. The pre-conditioning station may implement corona treatment to modify surface properties for improved ink adhesion or apply anti-flare spray to reduce laser reflection and improve cutting quality.

[0207] Additionally, the laser fabrication process implemented by the laser cutting subassembly is also different from “3D printing” processes. Laser fabrication implemented bythe laser cutting subassembly is a form of subtractive manufacturing that involves removing material from a larger piece of material, such as by cutting, etching, engraving, or scoring the material to achieve a fabrication result. By contrast, “3D printing” processes are a form of additive manufacturing that involves building an end product by adding layers of material. Some features and aspects of the disclosed embodiments could be used with certain additive manufacturing processes. Nevertheless, when used herein, the term “laser fabrication” generally refers to subtractive manufacturing rather than additive manufacturing processes.

[0208] In embodiments where the ink printing subassembly is configured to apply ink (in the form of toner) to the surface of the material 230 with a laser printing process, the ink printing subassembly includes a toner storage unit and a photoreceptor unit, such as an image drum. In operation, the image drum (or other suitable photoreceptor unit) is configured to transfer the toner from the toner storage unit to a region of the material 230 positioned within the housing 202 according to laser printing processes.

[0209] Additional details on embodiments where the ink printing subassembly implements laser printing technology are shown and described with reference to FIGS. 4A-B.

[0210] CNC / print system 200 also includes (i) one or more communications interfaces 221, (ii) one or more processors 223, (iii) tangible, non-transitory computer readable memory 225, (iv) one or more user interfaces 227, and (v) one or more power supplies (not shown).

[0211] In some embodiments, the CNC / print system implements an intelligent power management system that enables sharing of power supply components between laser and printing subsystems, significantly reducing system cost and complexity while maintaining reliable operation.

[0212] The intelligent power management system may implement power sequencing wherein: (i) laser and printing operations are temporally coordinated to avoid simultaneous peak power draw, (ii) laser power-up is staged during printer idle cycles, (iii) printhead maintenance operations occur during laser cooldown periods, and / or (iv) system operations are automatically queued to optimize power utilization. For example, the CNC / print system may perform laser cutting while printheads are capped and idle, then switch to printing operations while the laser cool downs.

[0213] Some embodiments include a shared high-voltage power supply that: (i) provides both laser power and printhead operating voltages, (ii) dynamically adjusts output based onactive subsystem requirements, (iii) includes fast-switching capability to alternate between subsystems, and / or (iv) maintains separate regulated outputs from a common power stage. This approach eliminates the need for separate expensive power supplies for each subsystem.

[0214] In some embodiments, the CNC / print system may implement power monitoring and regulation wherein: (i) current draw is continuously monitored across all subsystems, (ii) operating parameters are adjusted to maintain power draw within supply capabilities, (iii) thermal conditions are managed across shared power components, and / or (iv) power quality is maintained for sensitive components despite varying loads.

[0215] Some embodiments include energy storage elements that: (i) provide peak power during high-demand operations, (ii) recharge during idle periods, (iii) enable smoother transitions between operating modes, and / or (iv) provide backup power for safe shutdown procedures. In some embodiments, these elements include capacitor banks or small battery systems sized for short-duration peak loads rather than extended operation.

[0216] In some embodiments, the power management system implements intelligent job scheduling wherein: (i) processing steps are ordered to optimize power utilization, (ii) high- power operations are automatically distributed to avoid overlapping demands, (iii) powerintensive maintenance operations are scheduled during low-demand periods, and / or (iv) multiple jobs are queued to maintain efficient power utilization patterns.

[0217] In some embodiments, the system includes power-aware thermal management wherein: (i) cooling systems are shared between laser and printing components, (ii) airflow is directed to active components based on power utilization, (iii) thermal loads are balanced across shared heat sinks, and / or (iv) operating temperatures are managed to optimize power efficiency.

[0218] In some embodiments, the CNC / print system may implement fault protection wherein: (i) power monitoring circuits protect both subsystems, (ii) rapid shutdown capabilities protect sensitive components, (iii) separate low-voltage control circuits maintain system management during power transitions, and / or (iv) backup systems maintain critical functions during power anomalies.

[0219] Some embodiments include user feedback mechanisms that: (i) indicate power status and availability to users, (ii) provide estimates of processing time based on power scheduling, (iii) warn of potential delays due to power sequencing requirements, and / or (iv) suggest job optimizations to improve power utilization.

[0220] In some embodiments, the system maintains power utilization logs enabling: (i) optimization of power scheduling algorithms, (ii) identification of potential efficiency improvements, (iii) prediction of component wear based on power patterns, and / or (iv) validation of power supply performance over time.

[0221] The one or more communications interfaces 221 may include any one or more wired and / or wireless network interfaces, including but not limited to Ethernet, optical, WiFi, Bluetooth, or any other network interface now known or later developed that is suitable for enabling the CNC / print system 200 to receive data from other computing devices and CNC / print systems and / or transmit data to other computing devices and CNC / print systems.

[0222] In some embodiments, the CNC / print system implements secure connectivity and comprehensive telemetry capabilities to enable remote monitoring, updates, and emergency intervention. In some embodiments, the system supports over-the-air (OTA) firmware updates utilizing cryptographically signed packages to ensure authenticity and prevent unauthorized modifications. This secure update mechanism enables deployment of safety improvements, performance optimizations, and new features while maintaining system integrity and preventing malicious tampering.

[0223] In some embodiments, for diagnostic and safety analysis purposes, the system maintains a ring-buffer log of sensor data streams sampled, for example, at 100 Hz, capturing high-resolution telemetry from all critical sensors including temperature, airflow, position, and safety monitors. This forensic-grade logging enables detailed post-event analysis of system behavior, facilitating root cause analysis of any anomalies and supporting continuous improvement of safety algorithms. The ring-buffer architecture ensures that the most recent sensor history is always available while managing storage requirements.

[0224] In some embodiments, the system includes optional cellular connectivity providing a redundant communication path for critical safety functions. This cellular fallback enables remote halt commands to be issued even if primary network connectivity is compromised, allowing authorized personnel to immediately stop system operation from any location in emergency situations. The cellular interface operates independently from primary network connections, ensuring that safety-critical remote shutdown capabilities remain available under all operating conditions.

[0225] The one or more processors 223 may include any type of processor now known or later developed that is suitable for controller or operating the CNC / print system 200 (or subassemblies or other components thereof) to perform one or more (or all) of the disclosed features and functions, individually or in combination with one or more additional processors.

[0226] The one or more tangible, non-transitory computer-readable memory 225 is configured to store program instructions that are executable by the one or more processors 223. The program instructions stored in the tangible, non-transitory computer-readable memory 225, when executed by the one or more processors 223, cause the CNC / print system 200 to perform any one or more (or all) of the functions disclosed and described herein.

[0227] For example, in operation, after receiving a design file comprising ink printing instructions and laser cutting instructions, the one or more processors 223 are configured to execute program instructions that cause the CNC / print system 200 to (i) process the material 230 with the ink printing head 222 based on the ink printing instructions and (ii) process the material 230 with the laser cutting head 220 based on the laser cutting instructions.

[0228] In some embodiments, the CNC / print system 200 may receive a single design file that includes instructions for laser cutting and ink printing for execution, where the instructions for laser cutting are implemented by the laser cutting head 220 and the instructions for ink printing are implemented by the ink printing head 222. In other embodiments, the CNC / print system 200 may receive a first design file with instructions for laser cutting and a second design file for ink printing. In some examples, the design file may include a Scalable Vector Graphics (SVG) file containing both instructions for laser cutting and ink printing, where SVG metadata may indicate different colors for ink printing in color printing embodiments.

[0229] In some embodiments, for a region of the material 230 to be processed by both the ink printing head 222 and the laser cutting head 220, the functions include one or both of (i) applying ink to the region of the material 230 via the ink printing head 222 before applying the laser to the region of the material 230 via the laser cutting head 220, and / or (ii) applying the laser to the region of the material 230 via the laser cutting head 220, before applying ink to the region of the material 230 via the ink printing head 222.

[0230] In another example, the one or more processors 223 are configured to execute program instructions that cause the CNC / print system 200 to (i) print a first calibration design on a surface of the material 230 via the ink printing head 222, (ii) cut a second calibration design onthe surface of the material 230 via the laser cutting head 220, and (iii) calibrate operation of the ink printing head 222 and the laser cutting head 220 based at least in part on a comparison between (i) the first calibration design printed on the surface of the material 230 and (ii) the second calibration design cut (or engraved, etched, or scored) on the surface of the material 230.

[0231] In another example, the one or more processors 223 are configured to execute program instructions that cause the CNC / print system 200 to (i) collect temperature data from one or more temperature sensors located within the CNC / print system 200, such as within the interior portion 208 of the housing 202, on one or both of the laser cutting head 220 and / or the ink printing head 222, or any other suitable location, (ii) monitor one or more aspects of one or more operating temperatures of one or more aspects of the CNC / print system 200, and (iii) activate and / or control one or more cooling fans (including but not limited to exhaust fans 214) to control the temperature of the CNC / print system 200 during operation.

[0232] In some examples, the CNC / print system 200 also includes one or more cameras 290 that are configured to perform various features, including but not limited to, capturing images of the material for calibration. In some embodiments, the one or more cameras 290 may additionally or alternatively include one or more cameras on one or both of the laser cutting head 220 and / or the ink printing head 222. In some embodiments, the one or more cameras 290 include one or more cameras positioned at one or more locations within the interior portion 208 of the CNC / print system 200 and arranged to capture image data.

[0233] After capturing one or more images of the material 230 having both the first calibration design and the second calibration design with the one or more cameras 290, the CNC / print system 200 in some embodiments analyzes the image(s) to measure the actual alignment between the first and second calibration designs. The actual alignment can be compared with the expected alignment to determine whether and the extent to which an alignment of the one or both of the laser cutting head 220 and / or ink printing head 222 may need to be adjusted.

[0234] For example, if comparison of the first and second calibration images suggests that the two calibration images are 2 millimeters out of alignment, then the CNC / print system 200 can adjust the operation of one or both of the laser cutting head 220 and / or ink printing head 222 to account for the 2 millimeter misalignment.

[0235] In operation, the one or more tangible, non-transitory computer-readable memory 225 is / are also configured to store data that is both used in connection with performing the disclosed CNC / print system functions and generated via performing the disclosed CNC / print system functions. The tangible, non-transitory computer-readable memory 225 may be any type of one or more volatile storage medium such as random access memory, registers, cache, etc. and / or one or more non-volatile storage mediums such as read-only memory, a hard-disk drive, a solid-state drive, flash memory, and / or optical -storage device, and / or any other type of tangible, non-transitory computer-readable memory now known or later developed that is suitable for storing program instructions and data used by and / or generated by the one or more processors 223 in connection with performing the functions of the CNC / print system 200 disclosed herein.

[0236] The one or more user interfaces 227 may include any one or more of a keyboard, keypad, button(s), switch(es), monitor, touchscreen, mouse, trackpad, voice interface, or any other type of user interface now known or later developed that is suitable for use by a user of the CNC / print system 200 for interacting with the CNC / print system 200, including but not limited to configuring the CNC / print system 200 and / or controlling operation of the CNC / print system 200.

[0237] CNC / print system 200 also includes a scanner subassembly 218. In some embodiments, the CNC / print system 200 is configured to use the scanner subassembly 218 to capture image data corresponding to an item placed on the scanning bed 219 of the scanner subassembly 218.

[0238] Although example CNC / print system 200 shows the scanner subassembly 218 located at the top of the CNC / print system 200. In other examples, the scanner subassembly 218 could be located at other positions within the CNC / print system 200. For instance, rather than placing an item (e.g., a document, a card, object, or any other item than can be scanned) onto the scanning bed 219, closing the lid 204, and scanning the item with the scanner subassembly 218 to obtain image data associated with the scanned item, some embodiments may additionally or alternatively include a compartment, slot, or other enclosure (or semi enclosure) into which an item may be placed to obtain the image data associated with the scanned item.

[0239] In some embodiments, the CNC / print system 200 is configured to process the material 230 with one or both of the laser cutting subassembly and / or the ink printingsubassembly based at least in part on the image data associated with the scanned item that was obtained by the scanner subassembly 218.

[0240] In some examples, the CNC / print system 200 is configured to receive material 230 to be processed by the CNC / print system 200 via the material ingress 206. In operation, the material ingress 206 is configured to prevent laser light from escaping from within the housing 202 while the CNC / print system 200 is applying laser energy to the material 230 via the laser cutting head 220. In some embodiments, the material ingress 206 includes an optional material tray 207. In such embodiments, the material tray 207 is configured to facilitate the routing of material 230 from the material ingress 206 to the material feeding subassembly 210. In some embodiments, the material tray 207 is removable such that (i) the material tray 207 can be added to the material ingress 206 and used for certain types of materials (e.g., as flexible materials) that may benefit from a material tray 207 and / or (ii) the material tray 207 can be removed from the material ingress 206 when other types of materials (e g., larger or thicker materials) are to be processed by the CNC / print system 200 for which the material tray 207 may not be necessary or desirable. In some embodiments, the material tray 207 may include a door, hatch, or similar, that can be opened / closed to accept the material 230 inserted into the material ingress 206. In some configurations where the CNC / print system 200 includes a safety shutoff feature, when the laser cutting head 220 is emitting a laser beam 241, the CNC / print system 200 is configured to stop emitting the laser beam 241 from the laser cutting head 220 upon detecting that the door, hatch, or similar of the material tray 207 has been opened.

[0241] In some embodiments (both with and without a material tray 207), the material ingress 206 includes a material passthrough opening comprising at least a first curtain arranged to block laser light from exiting through the first material passthrough opening both (i) while material 230 is inserted through the first material passthrough opening of the material ingress 206 and (ii) while no material 230 is inserted through the first material passthrough opening. In some embodiments, the first curtain includes an array of resilient elements. In some examples, the resilient elements comprise silicone fingers. However, the resilient elements may comprise any type of structure suitable for blocking laser light from exiting through the material passthrough while material 230 is inserted into and / or removed from the CNC / print system 200 via the material ingress 206. In embodiments, the resilient elements are sufficient to block laserlight between about 350 nm - 500 nm in wavelength, having a laser power between about 500 mW - 100 W.

[0242] In some embodiments, the housing incorporates advanced materials and ergonomic features designed for safety, durability, and ease of maintenance. In some embodiments, the enclosure panels comprise fire-rated polymer / metal composite materials that provide structural rigidity while meeting flame resistance standards for laser processing equipment. This composite construction offers better thermal management compared to singlematerial enclosures, preventing exterior surfaces from reaching unsafe temperatures during extended operation while maintaining the mass and stiffness required for precision manufacturing.

[0243] In some embodiments, the system includes a laser-safe viewport compliant with EN 60825-4 standards for operator visibility during processing featuring an integrated autodimming LCD layer. This smart viewport automatically adjusts transparency based on detected laser activity, providing clear visibility during setup and ink printing operations while protecting users from laser exposure during cutting operations. The auto-dimming function responds within milliseconds to laser activation, eliminating the need for manual safety shutters or separate viewing modes.

[0244] In some embodiments, the system employs a modular filtration approach utilizing drop-in HEPA / activated-carbon cassettes equipped with RFID life tracking. These smart filter cassettes communicate remaining capacity to the system controller, enabling predictive maintenance scheduling and ensuring optimal air quality is maintained. The RFID system can be used to track cumulative operating hours, particle loading, and chemical saturation, automatically alerting operators when replacement is needed while preventing operation with exhausted filters.

[0245] In some embodiments, maintenance accessibility is enhanced through removable components including a combination crumb tray and drip gutter that serves dual purposes. This integrated collection system captures both laser cutting debris and excess ink from printhead maintenance operations, consolidating waste streams for simplified disposal. The shared design reduces component count while ensuring that both cutting residue and liquid waste are properly contained and easily removed for cleaning.

[0246] In some configurations, the material tray 207 is inserted through the array of resilient elements, and material 230 is fed into the CNC / print system 200 via the material tray 207.

[0247] In some examples, the array of resilient elements is arranged in a plurality of rows of resilient elements, where the resilient elements in each row are staggered relative to the resilient elements in adjacent row(s). In some examples, the array of resilient elements includes resilient elements having different dimensions. In some examples, the array of resilient elements is arranged in a plurality of rows of resilient elements, where the resilient elements include resilient elements having at least two different dimensions, and where the resilient elements in each row are staggered relative to the resilient elements in adjacent row(s).

[0248] In some embodiments, the material passthrough opening is similar to or the same as any of the material passthrough opening embodiments shown and described in U.S. App. 18 / 772,152, titled “Systems and Methods for Laser Fabrication,” filed on Jul. 13, 2024, and currently pending, including but not limited to the embodiments shown and described with reference to Figures 9A, 9B, 10A, 10B, and 10C of U.S. App. 18 / 772,152. As stated earlier, the entire contents of U.S. App. 18 / 772,152 are incorporated herein by reference.

[0249] Material 230 fed into the CNC / print system 200 via the material ingress 206 is guided through the CNC / print system 200 via the material feeding subassembly 210. The material feeding subassembly includes a set of cylindrical rollers 242, 243, 244, 246, 247, and 248. The set of cylindrical rollers 242, 244, 246, and 248 is arranged to (i) receive material 230 inserted into the CNC / print system 200 via the material ingress 206, and (ii) while the CNC / print system 200 is processing the material 230, move at least a portion of the material 230 through the interior portion 208 of the housing 202 and out of the housing 202 via the material egress 226.

[0250] In some embodiments, the material feeding subassembly 210 is configured to guide the material 230 through the interior portion 208 of the housing 202 such that a surface of the material 230 processed by the laser cutting head 220 is kept within a threshold distance of a focal length of a laser beam 241 emitted from the laser cutting head 220.

[0251] In some embodiments, the material feeding subassembly 210 comprises one or more sprung members configured to hold the material 230 within the threshold distance of the focal length of the laser beam 241 emitted from the laser cutting subassembly while the material230 is processed by the laser cutting head 220. In operation, the one or more sprung members enable the CNC / print system 200 to accommodate material 230 having different thicknesses.

[0252] In some embodiments, such as the example of FIG. 2A, the one or more sprung members are or comprise the bottom set of cylindrical rollers 246, 247, and 248 arranged along the bottom of the material feeding subassembly 210. In the example embodiment of FIG. 2A, the material ingress 206 (i) receives material 230 that is inserted into the CNC / print system 200, and (ii) guides the material 230 into the material feeding subassembly 210. The material feeding subassembly 210 is arranged to receive the material 230 between the top set of cylindrical rollers (242, 243, and 244) and the bottom set of cylindrical rollers (246, 247, and 248).

[0253] The bottom set of cylindrical rollers (246, 247, and 248) is sprung (or spring- loaded) whereas the top set of cylindrical rollers (242, 243, and 244) is fixed. When material 230 is fed into the material feeding subassembly 210, the spring-loaded bottom set of cylindrical rollers (246, 247, and 248) is pushed downward by the material 230, but the spring-loading mechanism holds the material 230 firmly between the top set of cylindrical rollers (242, 243, and 244) and the bottom set of cylindrical rollers (246, 247, and 248). A thinner piece of material 230 inserted into the material feeding subassembly 210 pushes down (or deflects) the bottom set of cylindrical rollers (246, 247, and 248) less than a thicker piece of material 230.

[0254] The top set of cylindrical rollers (242, 243, and 244) engages the top surface of the material 230, and the bottom set of cylindrical rollers (246, 247, and 248) engages the bottom surface of the material 230. The top set of cylindrical rollers (242, 243, and 244) rolls clockwise to “pull” the material 230 from the material ingress 206 through the interior portion 208 of the housing 202 while the bottom set of cylindrical rollers (246, 247, and 248) rolls counterclockwise to “push” the material 230 from the material ingress 206 through the interior portion 208 of the housing 202. In this manner, the top set of cylindrical rollers (242, 243, and 244) and the bottom set of cylindrical rollers (246, 247, and 248) work together to move the material 230 through the interior portion 208 of the housing 202 to facilitate both (i) ink printing onto the surface of the material 230 via the ink printing head 222 and (ii) laser fabrication (e.g., cutting, etching, engraving, scoring, etc.) of the material 230 via the laser cutting head 220.

[0255] In some embodiments, the material feeding subassembly 210 is further configured to support emergency material ejection as part of the system's active mitigation capabilities. Upon detection of safety events such as combustion or system faults, the cylindrical rollers canrapidly reverse or accelerate to advance material away from hazard zones, working in conjunction with the auto-eject rollers to move material more than 50 mm from the processing area within milliseconds of fault detection.

[0256] When processing “rigid” material 230 (e.g., wood, acrylic, metal, thicker paper, cardboard, and other material that cannot (or at least should not) be bent or folded), the top set of cylindrical rollers (242, 243, and 244) and the bottom set of cylindrical rollers (246, 247, and 248) work together to move the “rigid” material 230 from the material ingress 206 through the interior portion 208 of the housing 202 for processing by one or both of the ink printing head 222 and / or the laser cutting head 220, and then out of the CNC / print system 200 via the material egress 226. Similar to the material ingress 206, the material egress 226 is also configured to prevent laser light from escaping from within the housing 202 while the CNC / print system 200 is applying laser energy to the material 230 via the laser cutting head 220.

[0257] In some embodiments, the material egress 226 includes a second material passthrough opening comprising at least one curtain arranged to block laser light from exiting through the second material passthrough opening both (i) while material 230 is exiting from the second material passthrough opening of the material egress 226 and (ii) while no material 230 is exiting from the second material passthrough opening. In some embodiments, the at least one curtain includes an array of resilient elements. In some examples, the resilient elements comprise silicone fingers.

[0258] In some examples, the array of resilient elements for the material egress 226 is arranged similarly to (or the same as) the array of resilient elements for the material ingress 206. For example, in some embodiments, the array of resilient elements is arranged in a plurality of rows of resilient elements, where the resilient elements in each row are staggered relative to the resilient elements in adjacent row(s). In some examples, the array of resilient elements includes resilient elements having different dimensions. In some examples, the array of resilient elements is arranged in a plurality of rows of resilient elements, where the resilient elements include resilient elements having at least two different dimensions, and where the resilient elements in each row are staggered relative to the resilient elements in adjacent row(s).

[0259] In some embodiments, the second material passthrough opening for the material egress 226 is similar to or the same as any of the material passthrough opening embodiments shown and described in U.S. App. 18 / 772,152, titled “CNC / print systems and Methods for LaserFabrication,” filed on Jul. 13, 2024, and currently pending, including but not limited to the embodiments shown and described with reference to Figures 9A, 9B, 10A, 10B, and 10C of U.S. App. 18 / 772,152, which is incorporated herein by reference.

[0260] For “flexible” material 230 (e.g., paper, thinner cardboard, thin plastics, and other material than can be folded or bent), in some configurations, the top set of cylindrical rollers (242, 243, and 244) and the bottom set of cylindrical rollers (246, 247, and 248) work together to move the “flexible” material 230 from the material ingress 206 through the interior portion 208 of the housing 202 for processing by one or both of the ink printing head 222 and / or the laser cutting head 220, and then loop the “flexible” material 230 back around to the bottom set of cylindrical rollers (246, 247, and 248). Since the bottom set of cylindrical rollers (246, 247, and 248) roll counterclockwise, the bottom set of cylindrical rollers (246, 247, and 248) additionally pushes the “flexible” material 230 back under the bottom of the bottom set of cylindrical rollers (246, 247, and 248) and out through the material ingress 206. In such scenarios, the material ingress 206 both (i) receives material 230 to be processed by the CNC / print system 200 and (ii) outputs material 230 that has been processed by the CNC / print system 200.

[0261] In some configurations, the CNC / print system 200 includes a material store 209 configured to hold material 230 (e.g., flexible material) to be processed by the CNC / print system 200. In some such configurations, the bottom set of cylindrical rollers (246, 247, and 248) may be arranged to pull material 230 from the material store 209, route the material 230 from the bottom set of cylindrical rollers (246, 247, and 248) and around to the top set of cylindrical rollers (242, 243, and 244), which in turn, push the material 230 through the interior portion 208 of the housing 202 for processing by one or both of the ink printing head 222 and / or the laser cutting head 220.

[0262] The material 230 has a top side and a bottom side. In the example shown in the FIG. 2A, the CNC / print system 200 is configured so that the laser cutting head 220 and the ink printing head 222 are both arranged to process the top side of the material 230, i.e., the laser cutting head 220 processes (cuts, etches, etc.) and the ink printing head 222 processes (prints on) the same side of the material 230. In alternative configurations, the CNC / print system 200 is configured so that the laser cutting head 220 is arranged to process the top side of the material 230 and the ink printing head 222 is arranged to process the bottom side of the material 230. And in other configurations, the CNC / print system 200 is configured so that the laser cuttinghead 220 is arranged to process the bottom side of the material 230 and the ink printing head 222 is arranged to process the top side of the material 230. In still further embodiments, the CNC / print system 200 may be configured so that one or both the laser cutting head 220 and ink printing head is arranged to process both the top and bottom sides of the material 230.

[0263] In some examples, the ink printing head 222 applies ink to one side of the material 230, the material 230 is flipped over (e.g., similar mechanisms to double-sided printing), and then laser processing is performed by the laser cutting head 220 on the opposite side of the material 230. In operation, processing the material on each side in such a manner may reduce the likelihood of smudging or other cosmetic effects to the content (e.g., text, images, etc.) printed on the opposite side of the material 230. For material 230 that is printed on both sides, some embodiments may include printing (with the ink printing head 222) on the first side, followed by printing (with the ink printing head 222) on the second side, followed by laser processing (with the laser cutting head 220) on the first and / or second side.

[0264] Fig. 2B shows aspects of another example material feeding subassembly 211 for use with an example CNC / print system 200 for laser fabrication and ink printing according to some embodiments.

[0265] The material feeding subassembly 211 in FIG. 2B is similar to the material feeding subassembly 210 in FIG. 2A, except that the material feeding subassembly 211 in FIG. 2B includes (i) a particular example implementation of spring loading mechanisms 250 and 252 for the bottom set of cylindrical rollers 246 and 248, respectively, and (ii) a material platform 240 that supports the material 230 while the CNC / print system 200 is processing the material 230 via one or both of the ink printing head 222 and / or the laser cutting head 220.

[0266] In the example of FIG. 2B, the top set of cylindrical rollers 242 and 244 interface with the top of the material 230 and rotate clockwise to “pull” the material 230 through the CNC / print system for processing by the ink printing head 222 and / or the laser cutting head 220.

[0267] Rather than interfacing with the bottom surface of the material 230 as in the material feeding subassembly 210 of FIG. 2A, the bottom set of cylindrical rollers 246 and 248 in material feeding subassembly 211 of FIG. 2B instead support the material platform 240. In operation, the bottom set of cylindrical rollers 246 and 248 can roll clockwise or counterclockwise to facilitate raising and / or lowering the material platform 240 to support materials 230 of differing thicknesses.

[0268] For example, when “thick” material 230 is received by the material feeding subassembly 211, the “thick” material 230 pushes the material platform 240 downward so that the material 230 is held firmly between the material platform 240 and the top set of cylindrical rollers 242 and 244.

[0269] Cylindrical roller 248 is joined to pivot arm 261 which is supported by spring 262. As the material platform 240 is pushed downward (to accommodate the “thick” material 230), the pivot arm 261 attached to the cylindrical roller 248 is also pushed downward along path 260 against the upward force of spring 262. The spring 262 is sufficiently resilient to compress when the material platform 240 is pushed downward to accommodate the material 230, but also sufficiently stiff to push the material platform 240 upwards with enough force to hold the material 230 firmly between the material platform 240 and the top set of cylindrical rollers 242 and 244.

[0270] Similarly, cylindrical roller 246 is joined to pivot arm 264 which is supported by spring 265. As the material platform 240 is pushed downward (to accommodate the “thick” material 230), the pivot arm 264 attached to the cylindrical roller 246 is also pushed downward along path 263 against the upward force of spring 265. The spring 265 is sufficiently resilient to compress when the material platform 240 is pushed downward, but also sufficiently stiff to push the material platform 240 upwards with enough force to hold the material 230 firmly between the material platform 240 and the top set of cylindrical rollers 242 and 244.

[0271] By supporting the material platform 240 with enough upward force to hold the material 230 firmly between the material platform 240 and the top set of cylindrical rollers 242 and 244, the spring loaded (or sprung) set of bottom cylindrical rollers 246 and 248 (in combination with the material platform 240 and the top set of cylindrical rollers 242 and 242) operate to hold the top surface of the material 230 within the threshold distance of the focal length of the laser beam 241 emitted from the laser cutting head 220 while the material 230 is processed by the laser cutting head 220.

[0272] The material feeding subassembly 210 can accommodate an extensive range of material thicknesses, from ultra-thin papers as light as 20 gsm to rigid substrates up to 2mm thick, representing over a 100-fold variation in material thickness. The spring-loaded bottom cylindrical rollers (246, 247, and 248) provide variable compression force that automatically adjusts based on material thickness and density. For delicate materials such as 20 gsm paper, thesprings apply minimal pressure to prevent crushing or tearing, while for thicker materials such as 400 gsm cardstock, the springs compress further while maintaining sufficient upward force to ensure proper material positioning. This adaptive pressure system enables seamless transitions between diverse material types without manual adjustment, maintaining consistent focal distance for the laser cutting head 220 and proper contact pressure for the ink printing head 222 across the entire range of supported materials.

[0273] FIG. 2B also shows a debris removal subassembly 290 positioned at the end of the material feeding subassembly 211. In some embodiments, the debris removal subassembly 290 includes, among other components, (i) a wiper assembly configured to wipe debris from a region of a surface of the material 230 after the CNC / print system 200 has processed the region of the material 230 with the laser cutting head 220, and (ii) a tray arranged to capture debris removed from the region of the material 230 by the wiper assembly.

[0274] To ensure precise material positioning throughout the processing cycle, the material feeding subassembly 211 may incorporate substrate-motion assurance mechanisms. In some embodiments, the system includes an Optical Coherence Flow (OCF) sensor utilizing mouse-type CMOS technology to measure XY displacement directly beneath the processing head with 1 kHz polling rate, providing high-resolution tracking of actual material movement. The system may additionally employ through-beam encoder pairs positioned at entry and exit rollers to establish absolute speed references, enabling detection of slip or stretch conditions by comparing actual material movement against commanded feed rates.

[0275] Some embodiments include closed-loop torque monitoring on the paper-feed stepper motor, implementing a torque proxy algorithm capable of detecting stall conditions within 10 milliseconds. This rapid stall detection prevents material damage and enables immediate corrective action. The system may further incorporate Lidar or Time-of-Flight (ToF) sensors that triangulate distance changes to detect substrate buckle, warp, or lifting conditions that could compromise processing quality or cause collisions with the processing heads.

[0276] The substrate-motion assurance system implements a graceful shutdown ladder triggered when detecting anomalous conditions, including delta-velocity variations exceeding ±5% or zero motion persisting for more than 30 milliseconds. This multi-tier shutdown protocol ensures safe system response while minimizing material waste and preventing damage to both the substrate and system components.II. Gantry Subassemblies and Head Configurations

[0277] FIG. 3A and FIG. 3B show different gantry subassembly embodiments. As described herein, the different gantry subassembly embodiments facilitate movement of a laser cutting head 320 and an ink printing head 322 along a first axis (e.g., the x-axis) (i) together with each other and / or (ii) independently of each other. While the gantry subassemblies move (or at least facilitate the movement of) the laser cutting head 320 and the ink printing head 322 along the first axis, the material feeding subassembly (e.g., material feeding subassembly 310 (FIG. 2A) or material feeding subassembly 311 (FIG. 2B)) is configured to move the material 330 to be processed by the laser cutting head 320 and the ink printing head 322 along a second axis (e.g., the y-axis) that is different than the first axis. In some embodiments, the first axis and the second axis are substantially perpendicular to each other.

[0278] Any of the gantry subassembly embodiments shown in FIGS. 3A and 3B can be used with any of the CNC / print system embodiments disclosed herein, including but not limited to CNC / print system 100 (FIGS. 1A-D), CNC / print system 200 (FIGS. 2A-B), CNC / print system 400 (FIG. 4A), CNC / print system 450 (FIG. 4B), CNC / print system 500 (FIG. 5A), and CNC / print system 550 (FIG. 5B).

[0279] FIG. 3A shows aspects of an example dual gantry subassembly 300 configured to facilitate movement of a laser cutting head 320 and an ink printing head 322 for use with an example CNC / print system for laser fabrication and ink printing according to some embodiments.

[0280] The example dual gantry subassembly 300 includes both (i) a first gantry 302 configured to facilitate movement of the ink printing head 322 back and forth along the x-axis and (ii) a second gantry 304 configured to move the laser cutting head 320 back and forth along the x-axis. In operation, the dual gantry subassembly 300 is configured to facilitate movement of the laser cutting head 320 and the ink printing head 322 independently of each other.

[0281] The dual gantry subassembly 300 provides several operational benefits. For example, while the CNC / print system is processing a region of the material with the laser cutting head 320 (e.g., by moving the laser cutting head 320 over a region of the material 330), the CNC / print system can move the ink printing head 322 along the first gantry 302 to a position that is away from the region of the material 330 being processed by the laser cutting head 320.

[0282] In some examples where the material 330 is to be processed via both the ink printing head 322 and the laser cutting head 320, the material feeding subassembly 310 is configured to move the material 330 back and forth along the y-axis under the ink printing head 322 and the laser cutting head 320, each of which is configured to move back and forth along the x-axis via their respective gantry.

[0283] While the ink printing head 322 is depositing ink onto the surface of the material 330 (or at least a portion of region of the material 330), the laser cutting head 320 in some embodiments can be moved over to one side of the second gantry 304. However, since movement of the ink printing head 322 and the application of ink onto the surface of the material 330 does not (or at least should not) affect the laser cutting head 320, the laser cutting head 320 need not be moved over to one side of the second gantry 304 during application of ink via the ink printing head 322.

[0284] But as described earlier, processing the material 330 with the laser cutting head 320 generates debris and other effluent. This debris and other effluent can, in some instances, build up on portions of the ink printing head 322, including but not limited to the one or more nozzles of the ink printing head 322 that are arranged to apply ink onto the material 330. Debris and / or other effluent can, in some circumstances, clog the nozzles or otherwise negatively affect the ability of the ink printing head 322 to dispense ink.

[0285] So, in some dual gantry embodiments, while the laser cutting head 320 is applying laser power to the material 330 (or at least a portion of region of the material 330) to cut, etch, score, etc. the material 330 either in the center or near the left side 312, the CNC / print system can move the ink printing head 322 over to the right side 314 away from the area where the laser cutting head 320 is processing the material 330. Or while the laser cutting head 320 is applying laser power to the material 330 (or at least a portion of region of the material 330) to cut, etch, score, etc. the material 330 either in the center or near the right side 314, the CNC / print system can move the ink printing head 322 over to the left side 312 away from the area where the laser cutting head 320 is processing the material 330.

[0286] Having the ability to move the ink printing head 322 independently of the laser cutting head 320 on a separate gantry enables the CNC / print system to “park” the ink printing head 322 away from the region of the material 330 being processed by the laser cutting head 320, thereby reducing the likelihood that debris and / or other effluent generated during the applicationof laser energy to the material 330 damages or otherwise negatively affects the operation of the ink printing head 322.

[0287] Some embodiments additionally or alternatively include a moveable printhead cover 324. In some embodiments, the printhead cover 324 can be manually placed over the ink printing head 322 prior to operating the laser cutting head 320, and then manually removed from the ink printing head 322 prior to operating the ink printing head 322 to apply ink.

[0288] However, in other embodiments, the moveable printhead cover 324 is motorized, and the CNC / print system can control the operation of the moveable printhead cover 324 to expose or conceal the ink printing head 322. For example, in such embodiments, the CNC / print system is configured to (i) conceal the ink printing head 322 via the moveable printhead cover 324 while the CNC / print system is processing the material 330 with laser cutting head 320, and (ii) expose the ink printing head 322 via the moveable printhead cover 324 while the CNC / print system is processing material 330 with the ink printing head 322.

[0289] In some embodiments, one or both of the laser cutting head 320 and / or ink printing head 322 are individually removable from their respective gantries.

[0290] For example, in some embodiments, the laser cutting head 320 may be removable from the second gantry 304 to facilitate the use of several different types of laser cutting heads. Having the ability to use different types of laser cutting heads can be advantageous in scenarios where a first laser cutting head for applying a first type of laser is preferable for processing (e.g., cutting, etching, engraving, scoring, etc.) a first type of material (or types of materials) and a second laser cutting head for applying a second type of laser is preferable for processing (e.g., cutting, etching, engraving, etc.) a second type of material. For example, a lower power laser may be preferable when processing paper or cardboard, and a higher power laser may be preferable when processing certain fabrics. And an even higher power laser may be preferable when processing acrylic, wood, or metal.

[0291] In addition to differently powered lasers, it may be preferable in some instances to process different types of materials with lasers that operate at different wavelengths or different ranges of wavelengths. For example, some materials tend to absorb certain wavelengths of laser light more than other wavelengths. And for such materials, it is advantageous to process the material with laser energy at wavelengths that the material tends to absorb rather than at wavelengths that the material tends to reflect.

[0292] Another advantage of having a removable laser cutting head 320 is that, if one laser cutting head becomes damaged or stops working, the damaged / non-working laser cutting head can be removed and replaced with a new / replacement laser cutting head.

[0293] In some embodiments, the CNC / print system implements a comprehensive cartridge-style architecture for consumables and serviceable components, enabling rapid field replacement without specialized tools or alignment procedures. The blower filter system, for example, may utilize modular filter slices that can be individually replaced as needed, allowing targeted maintenance of high- wear sections while preserving functional filter elements. Ink supplies may be supplied in user-replaceable cartridges with integrated chip-based authentication and level monitoring, ensuring consistent print quality while simplifying inventory management.

[0294] In some embodiments, the laser subsystem employs a keyed cassette design housing Class 4 laser diodes, with mechanical keying preventing incorrect installation and ensuring proper safety interlocks. This cassette architecture enables field replacement of laser sources without optical alignment or safety recertification, as all critical alignments are maintained within the cassette assembly. In some embodiments, the system includes pre-aligned optics modules that maintain factory calibration through the cartridge interface, eliminating the need for field alignment procedures while ensuring consistent beam quality and focus characteristics.

[0295] In some embodiments, the system expandability and diagnostics are enhanced through plug-and-play sensors featuring self-identification capabilities via I2C bus communication. Each sensor module may contain embedded identification data including sensor type, calibration parameters, and operational history, enabling automatic system configuration when sensors are installed or replaced. This self-identifying architecture simplifies troubleshooting, enables hot-swapping of sensor modules during maintenance, and ensures that sensor-specific calibration data travels with the physical sensor, maintaining system accuracy across component replacements.

[0296] In other example embodiments, the ink printing head 322 may be removable from the first gantry 302 to one or both of (i) facilitate the use of several different types of ink printing heads and / or (ii) facilitate temporary removal of the ink printing head during processing of the material 330 via the laser cutting head 320.

[0297] For example, different types of ink printing heads may be preferable for use with different types of materials or with different types of inks. For instance a piezoelectric ink printing head can be removed from the first gantry 302 and replaced with a thermal ink printing head. And then later, the thermal ink printing head can be removed from the first gantry 302 and replaced with the piezoelectric ink printing head.

[0298] Piezoelectric ink printing heads and thermal ink printing heads both use drop technology to place ink onto the surface of the material 330, but they use different processes.

[0299] A piezoelectric ink printing head includes microscopic piezoelectric elements that are built in to each print nozzle of the ink printing head. To deposit ink from the piezoelectric ink printing head onto the material 330, the piezoelectric ink printing head applies an electrical charge to the piezoelectric element while the piezoelectric ink printing head moves over the surface of the material 330. This electric charge applied to the piezoelectric element causes the nozzle to drop the ink from the nozzle onto the surface of the material 330. With a piezoelectric ink printing head, the CNC / print system has a great degree of control over how much ink the ink printing head deposits on the surface of the material 330 being processed by the CNC / print system. In operation, piezoelectric ink printing heads can deposit drops of ink of varying sizes onto the surface of a material 330 very precisely. Piezoelectric ink printing heads are well suited for applying UV-cured, aqueous, and solvent-based ink onto materials 330, such as papers, cardboard, and certain woods, acrylics, metals, and other materials.

[0300] A thermal ink printing head includes electric resistors built in to each print nozzle of the ink printing head. To deposit ink from the thermal ink printing head onto the material 330, the thermal ink printing head applies an electric current to the resistors in each nozzle. The electric current causes the resistors to heat up. The heat causes the ink in the nozzle to vaporize, which creates bubbles that expand rapidly in the print nozzle creating an intense heat. As this heat occurs, it will vaporize the ink, creating bubbles that will expand rapidly and “pop” onto the paper or substrate. After the ink has been deposited from the nozzle, the nozzle cools, receives more ink, and then the heat / expansion / pop process occurs again. Thermal ink printing heads are well suited for applying water-based and latex inks onto materials 330 such as textiles, woods, and other materials.

[0301] In addition to providing the flexibility to use differently-configured ink printing heads, another advantage of having a removable ink printing head is that, if one ink printing headbecomes damaged or stops working, the damaged / non-working ink printing head can be removed and replaced with a new / replacement ink printing head.

[0302] In some embodiments, when a head (laser or ink) is installed, the CNC / print system 200 is configured to query the head to determine attributes of the head, such as whether the head is a laser cutting head or an ink printing head. If the head is a laser cutting head, then the CNC / print system 200 may query the head to determine the type of laser, wavelength range, power range, and so on. And if the head is a print head, the CNC / print system 200 may query the head to determine the type of ink printing technology (e.g., piezoelectric or thermal), the resolution, the available colors, and so on.

[0303] Additional aspects of removable heads, any of which could be used with the embodiments disclosed herein, are shown and described in U.S. App. 16 / 670,526, titled “Multifunction Computer Numerically Controlled Machine,” filed on Oct. 31, 2019, and issued as U.S. Pat. 11,537,095 on Dec. 27, 2022, the entire contents of which are incorporated by reference.

[0304] FIG. 3B shows aspects of example single gantry subassembly configurations 350, 360, and 370 that are arranged to facilitate movement of a laser cutting head 320 and an ink printing head 322 for use with an example CNC / print system for laser fabrication and ink printing according to some embodiments. The laser cutting head 320 and the ink printing head 322 depicted in FIG. 3B are the same as or similar to the laser cutting head 320 and ink printing head 322, respectively, depicted in FIG. 3A.

[0305] In single gantry subassembly 350, the laser cutting head 320 and the ink printing head 322 are both configured to move back and forth along the x-axis via the single gantry 306 while the material feeding subassembly 310 moves the material 330 along the y-axis. In single gantry subassembly 350, the laser cutting head 320 and the ink printing head 322 can each be moved along the single gantry 306 independently of each other.

[0306] In single gantry subassembly 360, the laser cutting head 320 and the ink printing head 322 are in a side-by-side configuration next to each other along the x-axis. Like the single gantry subassembly 350, the laser cutting head 320 and the ink printing head 322 are both configured to move back and forth along the x-axis via the single gantry 306 while the material feeding subassembly 310 moves the material 330 along the y-axis. But unlike the single gantry subassembly 350, the laser cutting head 320 and the ink printing head 322 in single gantrysubassembly 360 are configured to move back and forth together along the x-axis via single gantry 306.

[0307] In single gantry subassembly 370, the laser cutting head 320 and the ink printing head 322 are in a side-by-side configuration next to each other along the y-axis. Like the single gantry subassembly 350, the laser cutting head 320 and the ink printing head 322 are both configured to move back and forth along the x-axis via the single gantry 306. But unlike the single gantry subassembly 350 (and like the single gantry subassembly 360), the laser cutting head 320 and the ink printing head 322 in single gantry subassembly 370 are configured to move back and forth together along the x-axis via single gantry 306.

[0308] One advantage of the single gantry subassembly 370 as compared to the single gantry subassemblies 350 and 360 is that single gantry subassembly 370 enables the laser cutting head 320 and the ink printing head 322 to both be moved all the way from the left side 312 to the right side 314, thereby increasing the effective area via which both the laser cutting head 320 and the ink printing head 322 can process the material 330 as compared to the single gantry subassemblies 350 and 360.

[0309] In one or more (or all) of the example gantry subassembly configurations shown and described with reference to FIGS. 3A-B, one or both of the laser cutting head 320 and / or the ink printing head 322 can be removed and replaced as described previously.

[0310] Various head-assembly architectures may be implemented in the CNC / print system to optimize different operational requirements. In some embodiments, the system implements a monolithic combo head wherein a single chassis houses both the print mechanism and laser sub-module. Such embodiments may include a swap-in laser diode cartridge versus a fixed diode or fiber delivery system, and may employ either co-planar or stacked z-offset configurations for the nozzles and optics.

[0311] Some embodiments implement co-linear tandem heads that share a common rail, comprising independent X-axis carriages linked by either a rigid or magnetic coupler. In such configurations, users may disengage the coupler to service one head without requiring realignment of the other head, thereby simplifying maintenance procedures while maintaining precise positioning capabilities.

[0312] In some embodiments, the CNC / print system includes a tool-changer carousel comprising a multi-dock bay that accepts discrete print, laser, UV-cure, plasma, or pen modules.These embodiments may employ automatic kinematic couplings to ensure repeatable Z-axis positioning and process gas connections when modules are exchanged.

[0313] Some embodiments implement a gantry-mounted galvo (i.e., flying galvo) configuration comprising a fixed print head combined with a stationary galvo-steered laser system. This architecture eliminates mass and inertia from the moving components, enabling high-speed engraving operations.

[0314] In some embodiments, the system includes a fiber-fed remote source architecture wherein a high-power fiber laser is located off-carriage. In such embodiments, laser power is delivered through a flexible armored conduit to a micro-objective mounted on the head, reducing the mass of the moving carriage while maintaining high laser power capability.

[0315] In some configurations, the ink printing head 322 may accommodate several different ink modules, e g., separate ink modules for depositing cyan, magenta, yellow, and black colored ink. In some configurations, the ink printing head 322 accommodates all four ink modules. In other configurations, the ink printing head 322 may accommodate one ink module while the other three colored ink modules are stored within the interior of the CNC / print system. In some such embodiments, the ink printing head 322 may be configured to (i) apply ink with a first ink module, (ii) after applying ink with the first module, store the first ink module at a first designated location within the interior of the CNC / print system, (iii) after storing the first ink module at the first designated location, pickup a second ink module from a second designated location within the interior of the CNC / print system, (iv) after picking up the second ink module, apply ink with the second ink module, (v) after applying ink with the second ink module, store the second ink module at the second designated location, (vi) after storing the second the second ink module at the second designated location, pickup a third ink module from a third designated location within the interior of the CNC / print system, (vii) and so on with the third and fourth ink modules, perhaps returning to any of the first, second, third, and / or fourth ink modules as needed to complete an ink printing project.

[0316] In some configurations, rather than separate ink modules, the CNC / print system may instead implement four separate ink printing heads 322 (one for each of the cyan, magenta, yellow, and black colored inks). In some such configurations, the CNC / print system may be configured to pickup a first ink printing head, apply ink via the first ink printing head, store the first ink printing head, pickup a second ink printing head, apply ink via the second ink printinghead, and so on in a manner similar to that described above with reference to the different ink modules. In such embodiments, the CNC / print system may be configured to pick up, print with, and deposit any of the several separate ink printing heads as needed to complete a printing project.

[0317] Further, in one or more (or all) of the example gantry subassembly configurations shown and described with reference to FIGS. 3A-B where the laser cutting head 320 and ink printing head 322 can be moved independently of each other, one of the heads can be moved (and perhaps “parked”) out of the way while the other head is processing material 330. For example, the laser cutting head 320 can be moved over to one side of the gantry subassembly while the ink printing head 322 is processing material and / or the ink printing head 322 can be moved over to one side of the gantry subassembly while the laser cutting head 320 is processing material.

[0318] FIG. 3C shows aspects of an example carriage 361 with a laser cutting head 323 and an ink printing head 321 in a side-by-side configuration according to some embodiments. The carriage 361 is configured to move back and forth along the gantry 307.

[0319] The carriage 361 of FIG. 3C is similar to the arrangements in FIG. 3B in that, like the ink printing head 322 and the laser cutting head 320 depicted in FIG. 3B, the ink printing head 321 and the laser cutting head 323 of carriage 361 are positioned next to each other in a side-by-side arrangement.

[0320] The laser cutting head 323 encloses a laser diode (not shown) and one or more focusing mirrors and / or lenses (not shown). In operation, the laser diode within the laser cutting head 323 emits the laser beam 329, and the one or more focusing mirrors / lenses within the laser cutting head 323 route / focus the laser beam 329 onto the surface of the material 330. In some embodiments, the laser diode may be, for example, a blue laser in the 400-5 OOnm range. However, any other suitable type of laser could be used.

[0321] The sealed enclosure of the laser cutting head 323 provides a laser-safe environment where the laser diode and focusing mirror(s) are protected from exposure to the contaminates and debris that are typically produced when processing the material 330 with the laser cutting head 323. The laser cutting head 323 also includes a fan 331 in the top / rear portion of laser cutting head 323 that is arranged to cool the laser cutting head 323 during operation.

[0322] In some embodiments, the laser cutting head employs passive thermal management using a copper slug heat sink coupled with a finned radiator, providing reliable cooling without moving parts or power consumption. Alternative embodiments may utilize heat pipe technology to transfer thermal energy from the laser sub-module to a remote radiator location, enabling flexible system packaging while maintaining effective heat dissipation.

[0323] For applications requiring precise temperature control, some embodiments incorporate active Peltier thermoelectric cooling with closed-loop temperature sensing, enabling bidirectional temperature control to maintain the laser diode within optimal operating parameters regardless of ambient conditions. In integrated printer / laser configurations, the system may implement a liquid cooling loop that shares coolant infrastructure with the existing printer fuser system, leveraging common components to reduce system complexity and cost while providing efficient thermal management for both subsystems. This shared thermal management approach enables synergistic operation where waste heat from one subsystem can be managed in coordination with the thermal requirements of the other.

[0324] In some embodiments, the laser cutting head 323 additionally includes one or more physical interfaces 337 (e.g., flex cable interface(s)) via which the laser cutting head 323 sends / receives control signaling and / or power. In some embodiments, the physical interface(s) 337 delivers power to the laser cutting head 323 while control signaling is transmitted / received via a wireless interface.

[0325] The ink printing head 321 includes (i) a black ink printhead 325 configured to deposit black ink 326 onto material 330 that is being processed by the CNC / print system, and (ii) a color ink printhead 327 configured to deposit color ink 328 (e.g., CMYK) onto the material 330 that is being processed by the CNC / print system. The laser cutting head 323 is configured to apply laser beam 329 to the material 330 that is being processed by the CNC / print system. In some embodiments, the ink printing head 321 also includes one or more physical interfaces 338 (e.g., flex cable interface(s)) via which the ink printing head 321 sends / receives control signaling and / or power. In some embodiments, the physical interface(s) 338 delivers power to the laser cutting head 323 while control signaling is transmitted / received via a wireless interface.

[0326] Although the example in FIG. 3C depicts separate interfaces 337 and 338 for the laser cutting head 323 and the ink printing head 321, respectively, some examples may instead implement a common interface for the carriage 361 via which the carriage 361 (and the inkprinting head 321 and laser cutting head 323 thereof) sends / receives control signaling and / or power.

[0327] In some embodiments, the ink printing head 321 includes one or more integrated circuits configured to control application of black ink 326 and color ink 328 onto the material 330. In some embodiments, the black ink printhead 325 and the color ink printhead 327 each include one or more integrated circuits configured to control application of the ink onto the material 330. In some embodiments, the laser cutting head 323 includes one or more integrated circuits configured to control application of the laser beam 329 onto the material 330. In some embodiments, the carriage 361 additionally or alternatively includes one or more integrated circuits configured to control operation of both the ink printing head 321 (including the black ink printhead 325 and the color ink printhead 327) and the laser cutting head 323.

[0328] In operation, the CNC / print system is configured to move the carriage 361 back and forth along the x-axis (via gantry 307) to apply the laser beam 329, black ink 326, and color ink 328 to the material 330. The downward firing configuration shown in FIG. 3C integrates well within the geometry of existing cartridge-type ink printers because existing cartridge-type ink printers often include enough space within the current enclosures to add a narrow laser cutting head on the end of the moveable carriage. Further, configuring a downward firing laser in side-by-side arrangement with ink printing head 321 (including the black ink printhead 325 and the color ink printhead 327) as depicted in FIG. 1C can be done without adding any additional height to the carriage 361, which can be particularly advantageous for low-profile inkjet printers.

[0329] However, because of the positioning of the ink printing head 321 relative to the laser cutting head 323, the laser beam 329 emitted from the laser cutting head 323 is applied to an area of the material 330 adjacent to an area of the material 330 onto which the ink printing head 321 applies the black ink 326 and the color ink 328 to the material 330. This difference between the locations where the inks and laser are applied to the material 330 may be desirable (or at least acceptable) for some applications. However, it may be desirable in some instances for the laser cutting head 323 to instead apply the laser beam 329 to an area of the material 330 that is closer to (or perhaps within the same area as) the area of the material 330 onto which the ink printing head 321 applies the ink, i.e., closer to or within the same area on which the black ink 326 and the color ink 328 are applied to the material 330.

[0330] FIG. 3D shows aspects of an example carriage 362 with a laser cutting head 323 and an ink printing head 321 in a side-by-side configuration that additionally includes a laser beam routing enclosure 332 according to some embodiments.

[0331] In some embodiments, the example carriage 362 depicted in FIG. 3D is the same (or substantially the same) in most (or all) material respects as the example carriage 361 depicted in FIG. 3C except that the example carriage 362 additionally includes the laser beam routing enclosure 332. In contrast to carriage 361 in FIG. 3C, carriage 362 in FIG. 3D is arranged to apply the laser beam 329 to the same general area of the material 330 onto which the ink printing head 321 applies the ink.

[0332] The laser beam routing enclosure 332 includes optical components that are arranged to route the laser beam 329 from the laser cutting head 323 to a position on the surface of the material 330 that is between (i) the location on the surface of the material 330 where the black printhead 325 applies the black ink 326 and (ii) the location on the surface of the material 330 where the color printhead 327 applies the color ink 328. Thus, the configuration depicted in FIG. 3D reduces (or eliminates) the difference in the print area between the ink printing head 321 and the laser cutting head 323 in FIG. 3C.

[0333] In operation, carriage 362 includes at least one ink printhead (e.g., at least the black ink printhead 325 or the color ink printhead 327) and at least one laser cutting head (e.g., laser cutting head 323), where the at least one ink printhead and the at least one laser cutting head are positioned in a side-by-side fashion.

[0334] The laser cutting head includes a laser diode that emits laser light into a sealed enclosure (e.g., laser beam routing enclosure 332). The sealed enclosure includes one or more optical components that are configured to apply the laser light emitted from the laser diode onto the surface to the material. For example, in some configurations, the optical components within the sealed enclosure include one or more turning mirror(s) arranged to direct the laser light emitted from the laser diode to one or more focusing lens(s) arranged to focus the laser light onto the surface of the material.

[0335] In the example shown in FIG. 3D, while a region 340 of the material 330 is positioned within the housing (e.g., housing 102 (FIGs. 1A-D), the CNC / print system is configured to (i) apply ink to the region 340 of material 330 positioned within the housing via one or both of the color ink printhead 327 and the black ink printhead 325 of the ink printinghead 321 (sometimes referred to as the ink printing subassembly), where color ink 328 from the color ink printhead 327 is applied to a first portion 342 of the region 340 and black ink 326 from the black ink printhead 325 is applied to a second portion 344 of the region 340, and (ii) apply the laser beam 329 to the region 340 of material positioned within the housing via the laser head 323 (sometimes referred to as the laser cutting subassembly), where the laser beam 329 from the laser head 323 is applied to a third portion 346 of the region 340, where the third portion 346 of the region 340 is positioned between the first portion 342 of the region 340 and the second portion 344 of the region 340.

[0336] FIG. 3E shows a cutaway view of the example carriage 362 of FIG. 3D with a laser cutting head 323 and an ink printing head 321 in a side-by-side configuration that includes a laser beam routing enclosure 332 according to some embodiments.

[0337] The cutaway view in FIG. 3E shows aspects of the optical components within the laser beam routing enclosure 332 that are arranged to route the laser beam 329 from the laser cutting head 323 to a position on the surface of the material 330, including the laser diode 333, the turning mirror 334, and the focusing lens 335.

[0338] In operation, the laser diode 333 emits the laser beam 329 toward the turning mirror 334 positioned at the top comer of the laser beam routing enclosure 332 opposite the laser diode 333. The laser turning mirror 334 is arranged to direct the laser beam 329 emitted from the laser diode 333 in a downward direction toward the material 330 between the black printhead 325 and the color printhead 327. The focusing lens 335 is arranged to focus the laser beam 329 onto the surface of the material 330.

[0339] FIG. 3F shows a cutaway view of an alternative example carriage 363 with a laser cutting head 323 positioned on top of an ink printing head 321 according to some embodiments. Like carriage 362 depicted in FIG. 3E, carriage 363 depicted in FIG. 3F also includes a laser beam routing enclosure 336. However, laser beam routing enclosure 336 in FIG. 3F is different from the laser beam routing enclosure 332 in FIG. 3E in that laser beam routing enclosure 336 in FIG. 3F is straight (or substantially straight) whereas laser beam routing enclosure 332 in FIG. 3E is L-shaped (or substantially L-shaped).

[0340] The laser diode 333 is arranged to emit the laser beam 329 in a downward direction toward the material 330 between the black printhead 325 and the color printhead 327,and the focusing lens 335 is arranged to focus the laser beam 329 onto the surface of the material 330.

[0341] Positioning the laser cutting head 323 on top of the ink printing head 321 enables the laser beam emitted from the laser diode 333 to be routed to the surface of the material 330 via the laser beam routing enclosure 336 without requiring one or more turning mirrors, thereby resulting in a laser beam routing enclosure 336 design that is simpler, lower cost, and lighter weight relative to the laser beam routing enclosure 332. Although the example carriage 363 in FIG. 3F is able to apply the laser beam 329 and the ink (including black ink 326 and the color ink 328) to the same places on the material 330 as carriage 362 in FIG. 3E, placing the laser cutting head 323 on top of the ink printing head 321 results in carriage 363 in FIG. 3F being taller than carriage 362 in FIG. 3E. The taller carriage 363 in FIG. 3F may be less desirable than the shorter carriage 363 in FIG. 3E in some scenarios.

[0342] FIG. 3G shows an example carriage 380 with a laser cutting head 390, a black printhead 325, and a color printhead 327 according to some embodiments. Like carriage 361 (FIG. 3C), carriage 362 (FIGS. 3D and 3E), and carriage 363 (FIG. 3F), carriage 380 is also configured to move back and forth along the gantry 307.

[0343] The laser cutting head 390 is connected to a laser (e.g., a laser diode) (not shown) that is separate from the laser cutting head 390 via a fiber optic cable 383. In operation, the laser beam 329 emitted by the laser (not shown) is routed from the laser to the laser cutting head 390 via the fiber optic cable 383. In some embodiments, the laser cutting head 390 includes one or more focusing lens(es) arranged to focus the laser beam 329 onto the surface of the material 330.

[0344] The black printhead 325 is connected to a black ink tank (not shown) that is separate from the black printhead 325 via a black ink feeder line 381. In operation, black ink is routed from the black ink tank to the black printhead 325 via the black ink feeder line 381.

[0345] The color printhead 327 is connected to a plurality of color ink tanks (not shown) that are separate from the color printhead 327 via a plurality of color ink feeder lines 382. In operation, color ink is routed from the plurality of color ink tanks to the color printhead 327 via the plurality of color ink feeder lines 382.

[0346] In some examples, the laser that emits the laser light that is routed to the laser cutting head 390 via the fiber optic cable 383 is located near the one or more ink tanks that are configured to provide ink to the printheads (the black printhead 325 and the color printhead 327)via the feeder lines 381, 382. Locating the laser and the ink tanks off to the side (rather than on the carriage 380) makes carriage 380 weight less than the carriages 361, 362, and 363 that include one or more (or all) of the laser (e.g., laser diode) and ink tanks for the ink printing head 321.

[0347] FIG. 3H shows a perspective view of example carriage 391 with combined air flow detection and material movement monitoring capabilities for fire prevention according to some embodiments, and FIG. 31 shows a bottom view of the example carriage 391 in FIG. 3H according to some embodiments.

[0348] In some typical CNC laser cutting and engraving systems, a laser head typically moves along both the x-axis and y-axis via precision stepper motors and / or belt-driven or linear rail mechanisms to process (e.g., cut, engrave, or similar) materials. During operation, the focused laser beam generates significant heat at the point where the laser beam contacts the material, often reaching temperatures sufficient to ignite combustible materials. To mitigate fire risks and improve cutting efficiency, some conventional systems employ forced air, typically compressed air or gas, directed at the cutting point through nozzles integrated into or attached to the laser head. This air flow serves several functions, including (i) dissipating heat, (ii) preventing material ignition, (iii) clearing debris away from the region of the material where the laser beam is applied to the material, and (iv) protecting optical (and other) components of the laser from smoke and particulate matter. Continuous (or substantially continuous) movement of the laser head facilitates creation of the desired cut pattern while also preventing the laser beam from dwelling too long at any single point, which could lead to excessive heat buildup and potential fire hazards.

[0349] Further, in some typical inkjet printing systems, the inkjet print head moves laterally along a single axis (typically the x-axis) while paper is fed perpendicularly (along the y- axis) through a series of rollers. To detect paper jams and ensure proper paper movement, conventional inkjet printing systems commonly employ a combination of mechanical sensors and optical detectors positioned at strategic points along the paper path separate from the inkjet printhead. Typical detection methods include rotating encoder wheels that maintain contact with the paper and generate pulses as the paper advances, optical sensors that detect the presence or absence of paper at specific checkpoints, and torque monitors on the paper feed motors. When the paper fails to reach or clear a sensor within an expected timeframe, or when the encoderwheel stops generating pulses while the feed motor is running, the printer’s control system interprets this as a paper jam condition. This triggers an error state, halting both the paper feed mechanism and print head movement to prevent damage to the printer components and avoid wasting ink on an improperly positioned substrate.

[0350] While the above-described technologies separately address aspects of paper movement detection in inkjet printing systems and air-assisted fire prevention in CNC laser cutting systems separately, inkjet printing systems that monitor paper movement in one dimension are not designed to handle fire risks associated with laser operations and laser systems with air assist capabilities typically lack sophisticated material movement detection mechanisms to prevent fire. This is because, in typical laser cutting machines, the laser head generally moves in both the x-dimension or the y-dimension when cutting. However, when a laser head is attached to a print head that only moves in one dimension (e.g., the x-dimension of a typical inkjet printhead), simply ensuring that the laser head is moving and that air or gas is being provided to the laser head may not be sufficient to prevent potential fire scenarios.

[0351] Therefore, for fire prevention (among other advantages) it is beneficial to monitor and maintain proper material movement through a CNC / print system while maintaining effective air flow. Accordingly, some embodiments include a specially-configured carriage 391 like the example carriage shown in FIGS. 3H and 31. Carriage 391 comprises (i) a laser cutting subassembly 392, (ii) an ink printing subassembly 396, (iii) at least one fan 393, (iv) one or more air passages 395a and 395b configured to direct airflow from the at least one fan 393 (or other suitable air source) toward a region of material positioned within the housing where the laser cutting subassembly 392 applies laser power to the region of material, (v) one or more airflow sensors 399a and 399b configured to detect whether sufficient airflow is being directed out of the air passages 395 a, 395b and toward the region of the material positioned within the housing where the laser cutting subassembly 392 applies laser power to the region of material (e.g., via focusing lens 394), and (vi) at least one material movement sensor 397 configured to monitor movement of the region of the material positioned within the housing. In some embodiments, the material movement sensor 397 is configured to monitor movement of the region of the material positioned within the housing near where the ink printing subassembly 396 applies ink to the region of material (e.g., via ink printing head 398). However, a goal in most implementations is to monitor the movement of the material to help reduce the risk of firescaused by the laser dwelling too long in a single location (or region) of the material. Therefore, some embodiments may additionally or alternatively include one or more temperature sensors configured to monitor a temperature of the region where the laser cutting subassembly is applying laser energy to the material during processing. Some such embodiments may additionally use temperature measurements of the material during processing in combination with measurements of the airflow and / or the material movement rate to adjust the airflow and / or material movement during processing to help further reduce the likelihood of fire resulting from the application of laser energy to the material.

[0352] In the example embodiment depicted in FIG. 3H, the at least one fan 393 is positioned on top of the carriage 391. However, in other embodiments, the at least one fan could be positioned on one side of the carriage 391. In some embodiments, the carriage 391 may additionally or alternatively include one or more fans positioned in any location suitable for providing airflow that can be directed via the air passages 395a and 395b to the material being processed by the laser cutting subassembly 392. Some embodiments may additionally or alternatively include other air sources, including but not limited to, for example (i) air sourced from compressed air or gas directed through nozzles integrated into or attached to the laser cutting subassembly 392, (ii) air sourced from the exhaust system comprising fans configured to pull air through the housing, or (iii) any other suitable source of air now known or later developed that is sufficient to provide air to the carriage 391. In operation, the air from the at least one fan 393 (or other suitable air source), can additionally be used for cooling the laser components within the laser cutting subassembly 392 and / or other components of the carriage 391.

[0353] In some embodiments, each of the one or more air passages 395a and 395b comprises (i) an ingress port near the at least one fan 393 (or other air source), (ii) an egress port directed toward the region of the material where the laser cutting subassembly 392 applies laser power to the region of material, and (iii) a hollow path connecting the ingress port to the egress port through a portion of the carriage 391. In some embodiments, the hollow path within the carriage 391 connecting the ingress port to the egress port runs within the carriage 391 along a lateral side of the carriage 391. In operation, the air passages 395a and 395b provide consistent cooling and debris removal while preventing flame-ups when the laser cutting subassembly 392 is applying laser power to the material during processing. In some embodiments, the hollowpath within one or more (or all) of air passages 395a, 395b includes cooling fins that extend into the airflow path to facilitate heat dissipation from the laser cutting subassembly 392. The cooling fins are configured to transfer heat from the laser diode and perhaps other components within the laser cutting subassembly 392 into the airflow passing through the air passages 395a, 395b. This dual-purpose configuration enables the airflow from fan 393 (or other suitable forced air source) to simultaneously (i) cool internal laser components via the cooling fins and (ii) provide sufficient air movement at the material surface for debris removal and fire prevention. In some instances, this integration of cooling fins within the air passages 395a, 395b helps optimize thermal management while also satisfying the safety and debris control functions of the forced air system.

[0354] In some embodiments, air flow sensor 399a is positioned at the egress port to air passage 395a, and air flow sensor 399b is positioned at the egress port to air passage 395b. In operation, the air flow sensors 399a and 399b, individually or in combination with each other, are configured to determine if sufficient airflow is being generated downward toward the material (e.g., to avoid situations where an air passage 395a or 395b is blocked, etc.). Given the importance for safety reasons of ensuring sufficient air is reaching the material surface at / around the point of contact with the laser light, traditional methods that use estimates of air flow and / or air flow rate based on the motion of the fan 393 (e.g., via a tachometer) are generally not sufficient because the speed of the fan is not a reliable indication of air flow and / or air flow rate when one or more of the air passages 395a, 395b are blocked. The airflow sensors 399a and 399b positioned at or near the egress ports to the air passages 395a and 395b, respectively, can measure air pressure and / or air flow rate far more accurately than traditional fan speed based methods. In some embodiments, each airflow sensor 399a, 399b comprises at least one of a pressure sensor (pilot tubes, orifice plates, etc ), a mass airflow sensor (e.g., hot wire, hot film, etc.), or an anemometer sensor (e.g., hot wire sensor, thermistor, sonic, digital, etc.).

[0355] In some embodiments, the at least one material movement sensor 397 comprises a non-contact sensor aimed at the region of the material positioned within the housing where the material is being processed by the CNC / print system (e.g., beneath the carriage 391). In some example configurations, the material movement sensor 397 is aimed at the region of the material positioned within the housing where the ink printing subassembly 396 applies ink (via the ink printing head 398) to the material being processed by the CNC / print system. However, thematerial movement sensor 397 in some example configurations may be implemented in a different location, e.g., in a different location on the carriage 391 or perhaps separate from the carriage 391 but in a location suitable to monitor material movement within the CNC / print system. In some examples, the at least one material movement sensor 397 comprises at least one of an optical sensor, a movement sensor, a proximity sensor, and / or a motion sensor. For instance, in some implementations, the material movement sensor 397 is or comprises an optical sensor that operates similar to a computer mouse sensor by emitting light toward the material surface and detecting the reflected light to measure small changes in material position, thus enabling real-time verification of material movement. In operation, the material movement sensor 397 continuously (or substantially continuously) monitors the material surface to detect deviations from expected movement parameters which might indicate problems such as material jams, improper positioning, or movement speeds below some minimum threshold movement rate. This non-contact sensing approach allows for reliable / accurate (and in some instances, more immediate) movement detection across different material types while avoiding physical contact that could potentially mark or damage the material surface or otherwise interfere with precise movement of the material during processing.

[0356] In some embodiments, a CNC / print system equipped with carriage 391 additionally includes one or more processors and tangible, non-transitory computer-readable media containing program instructions that, when executed by the one or more processors, cause the CNC / print system to trigger one or more safety responses when at least one of (i) the one or more airflow sensors 399a and 399b detect that the directed airflow exiting via the one or more air passages 395a and 395b, respectively, has deviated from one or more threshold airflow parameters and / or (ii) the at least one material movement sensor 397 detects that movement of the region of the material positioned within the housing has deviated from one or more threshold material movement parameters. In some embodiments, the at least one material movement sensor 397 detects that movement of the region of the material positioned within the housing where the ink printing subassembly 396 applies ink to the region of material has deviated from one or more threshold material movement parameters.

[0357] In some example embodiments, the CNC / print system triggers one or more safety responses when at least one of (i) the detected airflow measured at one or both of the airflow sensors 399a and 399b is below about 5 cubic feet per minute or (ii) the movement of the regionof the material positioned within the housing measured by the material movement sensor 397 is less than about 3 mm / second. In some embodiments, the CNC / print system is configured to adjust the threshold airflow and movement parameters used to trigger the safety response based at least in part on flammability characteristics of different materials being processed. For example, more flammable materials may require higher airflow rates above 5 cubic feet per minute and / or faster material movement speeds above 3 mm / second to prevent ignition, while less flammable materials may be safely processed with lower airflow rates and slower movement speeds. The CNC / print system may maintain material-specific safety thresholds in a database and automatically adjust the parameters when different materials are detected or selected for processing.

[0358] In some embodiments, the one or more safety responses comprise at least one of(i) ceasing to apply laser power to the region of material via the laser cutting subassembly 392,(ii) ceasing to move the carriage 391 (and the laser cutting subassembly 392 and ink printing subassembly 396 thereof), (iii) generating an alert, and / or (iv) notifying an operator. In some embodiments, when a safety response is triggered, the system is configured to additionally or alternatively cease laser operation and move the carriage 391 to a designated parked position within the housing away from the processing area. Moving the carriage 391 to the parked position away from the processing area can provide several advantages. For example, (i) it quickly moves the carriage 391 away from potentially hazardous conditions near flammable materials, (ii) it positions the carriage 391 in a known safe location where the carriage 391 and its subcomponents are protected from debris and effluent, and (iii) it facilitates easier operator access to address any material movement or airflow issues that triggered the safety response. The system may maintain multiple designated park positions and select the most appropriate park position based on the type of safety condition detected.

[0359] In some examples, carriage 391 comprises at least one of the one or more processors at least a portion of the tangible, non-transitory computer-readable media comprising the program instructions executed by the one or more processors to trigger the one or more safety responses when at least one of (i) the one or more airflow sensors 399a and 399b detect that the directed airflow exiting via the one or more air passages 395a and 395b, respectively, has deviated from one or more threshold airflow parameters and / or (ii) the at least one material movement sensor 397 detects that movement of the region of the material positioned within thehousing where the ink printing subassembly 396 applies ink to the region of material has deviated from one or more threshold material movement parameters.

[0360] Additional gantry and / or carriage configurations, any of which could be used with the embodiments disclosed herein, are shown and described in U.S. App. 17 / 511,000, titled “Mechanical System for High Positional Computing Numerically Controlled Applications,” filed on Oct. 26, 2021, and currently pending, the entire contents of which are incorporated herein by reference. The CNC / print system may implement various head-assembly architectures as described herein, including monolithic combo heads, co-linear tandem heads, tool-changer carousels, gantry-mounted galvo configurations, and fiber-fed remote source architectures.III. Converting Source Files to Motion Plans

[0361] A CNC / print system accepts a wide variety of user files, acting as source files that describe both the printed elements and the laser processing operations that a user wishes to execute. The system can accept all files that are typically sent to an ink printer, as well as files commonly used for laser cutting and engraving operations. Examples of source files include:

[0362] 1) Print-native files such as PDF files containing text, images, and vector graphics for printing, with optional cut lines or engraving areas; Word processing documents (.DOC, .DOCX) defining text and layout for printing with embedded cut patterns; PostScript files describing page layout, fonts, and graphics for high-quality printing; print spool files containing rasterized print data ready for ink deposition; text files ( TXT) for simple text printing with optional cut borders; spreadsheet files (.XLS, .CSV) for printing tabular data with cut formatting; and presentation files ( PPT, .PPTX) for printing slides with cut shapes.

[0363] 2) Image files (.JPG, .PNG, TIFF, .BMP) that define bitmaps for printing, engraving, or etching on surfaces.

[0364] 3) Vector files (.SVG) that define vector shapes for cutting, engraving, scoring, or printing on material.

[0365] 4) Manufacturing files such as .STL files defining three-dimensional objects for engraving or cutting operations, and CAD files describing both printed and cut elements.

[0366] 5) Composite files containing both print and cut instructions, defining regions for ink application and areas for laser processing with integrated workflows.

[0367] A source file represents a work surface or page with specified dimensions containing various elements requiring different processing methods. Some elements require ink printing with specific color management, halftoning, resolution settings, multi-pass printing coordination, and print head temperature management, while others require laser cutting or engraving with precise power control, speed settings, focus management, and multi-pass cutting strategies. A computer program converts the source file into a machine file that can be interpreted by the CNC / print system to perform both printing and cutting operations. The conversion process handles traditional print job processing including color separation, rasterization, font rendering, page layout, ink flow management, and print quality optimization, as well as vector processing for cutting operations including path optimization, power modulation, and focus control.

[0368] A single file is generated for both delivering electromagnetic energy for cutting and etching and printing with ink. The machine file describes the idealized motion and operations of the CNC / print system to achieve the desired outcome. For example, if the source file specifies a design requiring both full-color printing with specific resolution and color accuracy and laser cutting with precise registration, the machine file instructs the CNC / print system to coordinate between ink deposition, color mixing, print head management, laser activation, power control, and focus adjustment. The machine file can omit information such as specific timing coordination between print and cut operations, exact halftoning patterns for color reproduction, or precise thermal management details, which are determined during motion planning. The machine file can also add information such as instructions for head positioning, switching between operational modes, managing ink flow and print head cleaning, handling paper feeding and positioning, and coordinating between different subsystems.

[0369] In one example, the file will be split into print data and cut / engrave data and routed to the correct subsystem. The print data contains instructions for ink deposition, droplet placement, color management, halftoning patterns, print resolution settings, multi-pass printing coordination, ink flow control, print head temperature management, nozzle firing sequences, and color mixing ratios. The cut / engrave data contains instructions for laser power levels, cutting speeds, beam positioning, engraving depth control, focus adjustment, multi-pass cutting strategies, and thermal management. This separation allows each subsystem to optimize itsoperations independently while maintaining overall coordination through the motion planning system.

[0370] The conversion of the source file to the machine file may cause the CNC / print system to initialize print heads, perform nozzle checks and cleaning cycles, move appropriate heads to starting positions, manage material feeding and positioning, activate correct tools (ink jets with specific nozzle patterns and / or laser with appropriate focus), execute required operations including color transitions and ink mixing, manage print quality settings and laser power modulation, deactivate tools, perform maintenance cycles, switch between heads as needed, and return to home positions. The machine file coordinates multiple operational modes within a single workflow, including print job queuing, color calibration, material handling, debris management, and thermal control.

[0371] Once the machine file has been created, a motion plan for the CNC / print system is generated. The motion plan contains data determining the actions of all system components at different points in time, including both ink printing and laser cutting subsystems. A motion plan comprises streams of data describing electrical pulses indicating motor movement, voltages indicating desired laser output power, timing signals controlling ink droplet ejection from multiple nozzles, print head temperature controls, ink flow rate controls, material advance mechanisms, color mixing ratios, halftoning patterns, print resolution settings, laser focus parameters, cutting depth controls, and coordination signals between subsystems. Unlike source files and machine files, motion plans include temporal elements indicating time or time offset for each action, enabling coordinated operation where multiple actuators and subsystems work together for integrated results.

[0372] The motion plan will determine what head (ink or laser) will operate and when, and route the head accordingly. This includes managing physical positioning of different tool heads, ensuring proper clearance between operations, coordinating timing of ink curing or drying with subsequent laser operations, managing print head cleaning cycles, controlling ink flow to prevent clogging, coordinating multi-color printing sequences, managing laser thermal cycles, and ensuring proper focus maintenance. In one example, the actions may be serialized (e.g., print first, cut second) to ensure proper material handling, ink curing, thermal management, and optimal results. In another example, the ink and laser heads may be operated simultaneously.

[0373] For example, a machine file might include instructions to print a full-color design with specific resolution and color accuracy, manage ink curing and drying times, then move to laser cutting position and cut around the printed area with precise registration to printed features. The motion plan must consider that print heads cannot move instantly between positions, different ink colors may have different drying times, print heads may need cleaning between colors, laser heads require thermal management and focus adjustment, and material must be properly positioned and held during both printing and cutting operations.

[0374] The machine file is converted to the motion plan by the motion controller / planner, which may comprise high-performance microcontrollers or single board computers coupled to Digital Signal Processors (DSPs). The motion controller converts vector machine code into electrical signals driving motors, ink delivery systems, print head actuators, material handling mechanisms, laser systems, focus control systems, and thermal management components. The motion controller accounts for the exact state of both printing and cutting subsystems and physical limitations of each, including print head response times, ink flow characteristics, laser thermal requirements, material handling constraints, and coordination between subsystems.

[0375] The motion plan is the only stage that understands detailed physics of both printing and cutting subsystems, translating idealized machine files into implementable steps. For example, a particular CNC / print system might require specific ink drying times before laser cutting, particular head switching sequences to avoid collisions, specific nozzle firing patterns for optimal print quality, precise color calibration procedures, laser thermal management protocols, and coordinated material handling between printing and cutting operations. Each CNC / print system model requires precise tuning based on measured attributes including ink flow characteristics, print head performance, color accuracy capabilities, laser cutting precision, thermal management effectiveness, and material handling constraints.

[0376] The motion plan can be generated in real-time or pre-computed and stored. Instructions can be streamed wholly or in batches, with separate storage and management allowing optimization of different aspects such as print quality independent from cut quality, color management separate from cutting operations, and thermal management across both subsystems.

[0377] The motion plan can be augmented with machine vision feedback, using cameras to image the CNC / print system, material being processed, printed ink quality, color accuracy,print registration, laser cutting progress, and combinations thereof. By analyzing image data, the system determines if both printing and cutting operations function correctly, if ink has properly adhered before cutting begins, if color reproduction meets specifications, if print registration is maintained, if laser alignment matches printed features, and if errors occur in either subsystem. Error conditions include ink smearing, nozzle clogging, improper print registration, color shifts, laser misalignment, material movement between printing and cutting operations, thermal issues, and focus problems.IV. Laser and Ink Printing Component Configurations

[0378] FIG. 4A shows a block diagram illustrating aspects of selected CNC / print system components in an example CNC / print system 400 for laser fabrication and ink printing according to some embodiments where the laser cutting subassembly and the ink printing subassembly use separate lasers according to some embodiments.

[0379] The CNC / print system 400 includes both (i) a laser cutting subassembly 424 with a laser cutting head 420 configured to apply a laser 418 to the surface of material 430 processed by the CNC / print system 400 and (ii) an ink printing subassembly 423 that uses a laser printing process to apply ink (in the form of toner) to the surface of material 430 processed by the CNC / print system 400.

[0380] As mentioned earlier, in some embodiments, the CNC / print system is additionally or alternatively configured to apply ink to the surface of the material 430 via a laser printing process. The laser printing process implemented by the ink printing subassembly 423 is different than the laser fabrication process implemented by the laser cutting subassembly 424 despite both processes (and subassemblies) implementing lasers and laser technology.

[0381] The laser cutting subassembly 424 is similar to or the same as any of the laser cutting subassemblies described herein. Accordingly, the laser cutting head 420 component of the laser cutting subassembly 424 is likewise similar to or the same as any of the laser cutting heads described herein, including but not limited to laser cutting head 220 (FIGS 2A and 2B).

[0382] However, the ink printing subassembly 423 of CNC / print system 400 is different than the ink printing subassemblies described previously herein in that the previously-described ink printing subassemblies use an inkjet process (e.g. via a piezoelectric ink printing head and / ora thermal ink printing head) to apply ink onto material whereas the ink printing subassembly 423 uses a laser printing process to print ink (in the form of toner) onto the material 430.

[0383] The ink printing subassembly 423 includes, among other components, (i) an image drum 402 (or other suitable photoreceptor unit), (ii) one or more toner cartridges 404, (iii) an image drum charger 406, (iv) a transfer roller 460, (v) a fuser 462, (iv) a laser 408, and (v) an image drum cleaner 412.

[0384] In operation, the image drum charger 406 applies a positive electrical charge to the surface of the image drum 402 as the image drum 402 rotates (clockwise in the example shown in FIG. 4A) across the image drum charger 406. The laser 408 fires a laser beam along path 414 that is reflected via one or more mirrors 410 across the surface of the image drum 402 to imprint the image to be printed (e.g., text, images, etc.) onto the surface of the image drum 402 using a negative electrical charge.

[0385] The toner cartridge 404 slowly releases positively charged carbon toner particles onto the surface of the image drum 402 as the image drum 402 turns. The toner from the toner cartridge 404 is attracted to any areas of negative charge on the surface of the image drum 402 leaving positively charged areas of the image drum 402 without toner.

[0386] The transfer roller 460 applies a positive charge to the surface of the material 430. As the positively-charged material 430 passes the image drum 402, the negatively-charged toner on the image drum 402 is attracted to the positively-charged material 430, thereby transferring the toner in the shape / form of the image to be printed (e.g., text, images, etc.) from the image drum 402 onto the surface of the material 430.

[0387] The fuser 462 includes one or more heated rollers. After the toner has been transferred from the image drum 402 to the surface of the material 430, the heated roller(s) of the fuser 462 heat the toner on the surface of the material 430, thereby melting the toner to the surface of the material 430 resulting in the image (e.g., text, images, etc.) appearing on the surface of the material 430.

[0388] Residual toner remaining on the surface of the image drum 402 after imprinting the image onto the surface of the material 430 is then cleaned from the surface of the image drum 402 via the image drum cleaner 412 before the surface of the image drum 402 is recharged via the image drum charger 406.

[0389] After CNC / print system 400 has printed one or more images onto the surface of the material 430 via the ink printing subassembly 423, the CNC / print system 400 advances the material 430 to an area within the interior portion of the housing of the CNC / print system 400 where the laser cutting subassembly 424 performs laser fabrication procedures (e.g., cutting, etching, engraving, scoring, etc.) on the material 430. For example, in CNC / print system 400, the material feeding subassembly includes a plurality of cylindrical rollers 440, 442, 444, 446, and 448 that push the material 430 through the CNC / print system 400 for processing via one or both of the ink printing subassembly 423 and / or the laser cutting subassembly 424.

[0390] FIG. 4B shows a block diagram illustrating aspects of selected CNC / print system components in an alternative example CNC / print system 450 for laser fabrication and ink printing according to some embodiments where the laser cutting subassembly 425 and the ink printing subassembly 451 use a common laser 409 according to some embodiments.

[0391] Like the ink printing subassembly 423 of FIG. 4A, the ink printing subassembly 451 of FIG. 4B also includes, among other components, (i) an image drum 402, (ii) one or more toner cartridges 404, (iii) an image drum charger 406, (iv) a transfer roller 460, (v) a fuser 462, and (v) an image drum cleaner 412. Similarly, the components of the material feeding subassembly of CNC / print system 450 shown in FIG. 4B are the same as or substantially the same as the components of the material feeding subassembly of CNC / print system 400 shown in FIG. 4A. For example, the plurality of cylindrical rollers 440, 442, 444, 446, and 448 that push the material 430 through the CNC / print system 400 for processing via one or both of the ink printing subassembly 423 and / or the laser cutting subassembly 424 in FIG. 4A operate in the same manner as the plurality of cylindrical rollers 440, 442, 444, 446, and 448 that push the material 430 through the CNC / print system 450 for processing via one or both of the ink printing subassembly 451 and / or the laser cutting subassembly 425 in FIG. 4B.

[0392] The laser printing process implemented by the ink printing subassembly 451 of FIG. 4B is the same as or substantially the same as the laser printing process implemented by the ink printing subassembly 423 of FIG. 4 A, and the laser fabrication process implemented by the laser cutting subassembly 425 is the same as or substantially the same as the laser fabrication process implemented by any of the other laser cutting subassemblies disclosed herein, except that the ink printing subassembly 451 and the laser cutting subassembly 425 both use laser 409.

[0393] When the CNC / print system 450 is processing the material 430 via the ink printing subassembly 451, the laser 409 fires a laser beam along path 413 to one or more mirrors 411, which in turn reflect the laser beam along path 415 and across the surface of the image drum 402 to imprint the image to be printed (e.g., text, images, etc.) onto the surface of the image drum 402 using a negative electrical charge. The remaining aspects of the laser printing process implemented via the ink printing subassembly 451 of FIG. 4B are the same or substantially the same as the laser printing process implemented via the ink printing subassembly 423 of FIG. 4A described previously.

[0394] When the CNC / print system 450 is processing the material 430 via the laser cutting subassembly 425, the laser 409 fires the laser beam along path 413 to the one or more mirrors 411, which in turn reflect the laser beam along path 417 to the laser cutting subassembly 425. One or more mirrors and / or focusing elements 426 direct the laser beam received via path 417 to the laser cutting head 420, which in turn focuses the laser beam 419 onto the surface of the material 430. In operation, the laser cutting head 420 is configured to use the laser energy from laser 409 to perform laser fabrication procedures (e.g., cutting, etching, engraving, scoring, etc.) in substantially the same manner as the other laser cutting head examples described herein.V. Modular CNC / print System Configurations

[0395] FIG. 5A shows an example modular configuration of a CNC / print system 500 for laser fabrication and ink printing according to some embodiments.

[0396] CNC / print system 500 includes a laser cutting subsystem 501 and an ink printing subsystem 503. In the example CNC / print system 500, the laser cutting subsystem 501 is on top of the ink printing subsystem 503. In other embodiments, the ink printing subsystem 503 may instead be on top of the laser cutting subsystem 501. In some embodiments, the ink printing subsystem 503 and the laser cutting subsystem 501 may be operated separately, and combined when needed to perform joint laser cutting and ink printing operations.

[0397] The laser cutting subsystem 501 includes, among other components / subassemblies, (i) a laser cutting head 520, (ii) an exhaust system 512 that includes one or more fans, filters, and / or exhaust ports, and (iii) a control subassembly 521 that includes, among other components, one or more processors, and tangible, non-transitory computer-readable memory configured to store program instructions executable by the one or more processors. In operation,the one or more processors of the control subassembly 521 execute the program code to perform any of the laser fabrication processes disclosed herein.

[0398] The laser cutting subsystem 501 also includes a lid 504 with a lid camera 505. The lid 504 is openable to reveal the interior portion 508 of the housing 502 of the CNC / print system 500. In some examples, the lid 504 and / or lid camera 505 are the same as or similar to any of the lid and / or lid camera embodiments shown and described in U.S. App. 18 / 772,152, titled “Systems and Methods for Laser Fabrication,” fded on Jul. 13, 2024, and currently pending, including but not limited to the embodiments shown and described with reference to Figures 6A, 6B, 7A, and 7B of U.S. App. 18 / 772,152, the entire contents of which are incorporated herein by reference.

[0399] The ink printing subsystem 503 includes, among other components / subassemblies, (i) ink printing head 522, and (ii) a control subassembly 523 that includes, among other components, one or more processors, and tangible, non-transitory computer-readable memory configured to store program instructions executable by the one or more processors. In operation, the one or more processors of the control subassembly 523 execute the program code to perform any of the ink printing processes disclosed herein.

[0400] In some embodiments, the components of control subassembly 521 and control subassembly 523 are combined into a single control subassembly comprising processors and computer memory with program instructions for performing the functions of CNC / print system 550. In some configurations, the control subassembly 521 and control subassembly 523 are separate, but communicate with each other to coordinate laser cutting and ink printing operations between and among the laser cutting subsystem 501 and the ink printing subsystem 503.

[0401] For rigid material 530 to be processed by the laser cutting subsystem 501 of CNC / print system 500, the laser cutting subsystem 501 receives the rigid material 530 via material ingress 506a and uses the upper material feeding subassembly 510a to guide the rigid material 530 under the laser cutting head 520 for processing. After processing the rigid material 530 via the laser cutting head 520, the laser cutting subsystem 501 routes the processed material out of laser cutting subsystem 501 via material egress 526a.

[0402] In some embodiments, (i) the upper material feeding subassembly 510a guides the material 530 under the laser cutting head 520 along the y-axis, (ii) the laser cutting head 520 moves back and forth along the x-axis via a gantry subassembly, and (iii) one or more opticaland / or mechanical components within the laser cutting head 520 control the focal length of the laser beam emitted along the z-axis from the laser cutting head 520 to the surface of the material 530 processed by the laser cutting head 520.

[0403] In other embodiments, (i) the upper material feeding subassembly 510a guides the material 530 under the laser cutting head 520 along the y-axis, (ii) the laser cutting head 520 moves back and forth along one or both of the x-axis and / or the y-axis via a gantry subassembly, and (iii) one or more optical and / or mechanical components within the laser cutting head 520 control the focal length of the laser beam emitted along the z-axis from the laser cutting head 520 to the surface of the material 530 processed by the laser cutting head 520.

[0404] Examples of gantry subassemblies configured to move a laser cutting head back and forth along one or both of the x-axis and / or y-axis (or any other two axes) that can be used with the CNC / print system 500 (FIG. 5 A) and / or 501 (FIG. 5B), or any of the other CNC / print system embodiments disclosed herein are shown and described in U.S. App. 17 / 511,000, titled “Mechanical System for High Positional Computer Numerically Controlled Applications,” filed on Oct. 21, 2021, published as U.S. Pub. 2023 / 0128807 on Apr. 27, 2023, and currently pending. The entire contents of U.S. App. 17 / 511,000 are incorporated herein by reference.

[0405] Similarly, for rigid material 530 to be processed by the ink printing subsystem 503 of CNC / print system 500, the ink printing subsystem 503 receives the rigid material 530 via material ingress 506b and uses the lower material feeding subassembly 510b to guide the rigid material 530 under the ink printing head 522 for processing. After processing the rigid material 530 via the ink printing head 522, the ink printing subsystem 503 routes the processed material out of ink printing subsystem 503 via material egress 526b.

[0406] For flexible material 531 (e.g., paper, cardboard, or other flexible material), the CNC / print system 500 uses the combination of the upper material feeding subassembly 510a and the lower material feeding subassembly 510b to route the flexible material 531 through the interior portion 508 of the CNC / print system 500 (i) from the laser cutting subsystem 501 to the ink printing subsystem 503 and / or (ii) from the ink printing subsystem 503 to the laser cutting subsystem 501.

[0407] FIG. 5B shows another example modular configuration of a CNC / print system 550 for laser fabrication and ink printing according to some embodiments.

[0408] CNC / print system 550 includes a laser cutting subsystem 551 and an ink printing subsystem 553. In some embodiments, the ink printing subsystem 553 and the laser cutting subsystem 551 may be operated separately, and combined when needed to perform joint laser cutting and ink printing operations.

[0409] The laser cutting subsystem 551 includes, among other components / subassemblies, (i) a laser cutting head 520, (ii) an exhaust system 512 that includes one or more fans, fdters, and / or exhaust ports, and (iii) a control subassembly 521 that includes, among other components, one or more processors, and tangible, non-transitory computer-readable memory configured to store program instructions executable by the one or more processors. In operation, the one or more processors of the control subassembly 521 execute the program code to perform any of the laser fabrication processes disclosed herein.

[0410] The laser cutting subsystem 551 also includes a lid 504a (shown closed in FIG. 5B) with a lid camera 505. The lid 504a is openable to reveal the interior portion 508 of the housing 502 of the CNC / print system 500. In some examples, the lid 504a and / or lid camera 505 are the same as or similar to as any of the lid and / or lid camera embodiments shown and described in U.S. App. 18 / 772,152, titled “Systems and Methods for Laser Fabrication,” filed on Jul. 13, 2024, and currently pending, including but not limited to the embodiments shown and described with reference to Figures 6A, 6B, 7A, and 7B of U.S. App. 18 / 772,152, the entire contents of which are incorporated herein by reference.

[0411] In some embodiments, the laser cutting subsystem 551 may additionally or alternatively include a side access panel 507. For example, some embodiments of the laser cutting subsystem 551 may include the lid 504a but not the side access panel 507, some embodiments may include the side access panel 507 but not the lid 504a, and some embodiments may include both the side access panel 507 and the lid 504a. In operation, material 530 can be placed into the laser cutting subsystem 551 via the side access panel 507 for processing by the laser cutting head 520 of the laser cutting subsystem 551. In such embodiments, the side access panel 507 may include an access door and / or a plurality of resilient members (similar to the material ingress 506 and material egress 526) that are arranged to prevent laser light from the laser cutting head 520 from escaping the housing 502 while the laser cutting subsystem 551 is processing material 530 with the laser cutting head 520.

[0412] In some configurations, the laser cutting subsystem 551 includes a first access panel on one side of the housing 502 and a second access panel on the opposite side of the housing 502. Such embodiments enable larger / oversized material to be processed by the laser cutting head 520 since portions of the material can protrude from the housing 502 via one or both of the first access panel and / or the second access panel while other portions of the material are contained within the housing 502 while laser cutting subsystem 551 is processing the material via the laser cutting head 520.

[0413] The ink printing subsystem 503 includes, among other components / subassemblies, (i) ink printing head 522, and (ii) a control subassembly 523 that includes, among other components, one or more processors, and tangible, non-transitory computer-readable memory configured to store program instructions executable by the one or more processors. In operation, the one or more processors of the control subassembly 523 execute the program code to perform any of the ink printing processes disclosed herein.

[0414] In some embodiments, the components of control subassembly 521 and control subassembly 523 are combined into a single control subassembly comprising processors and computer memory with program instructions for performing the functions of CNC / print system 550. In some embodiments, the components of control subassembly 521 and control subassembly 523 are combined into a single control subassembly comprising processors and computer memory with program instructions for performing the functions of CNC / print system 550. In some configurations, the control subassembly 521 and control subassembly 523 are separate, but communicate with each other to coordinate laser cutting and ink printing operations between and among the laser cutting subsystem 551 and the ink printing subsystem 553.

[0415] The ink printing subsystem 553 also includes a lid 504b that is openable to reveal a scanner subassembly 518. The scanner subassembly 518 is the same as or similar to the other scanner subassemblies disclosed herein.

[0416] When processing material 530 (rigid or flexible), the material handling subassembly 510 facilitates routing of the material 530 (a) from the material ingress 506 at the ink printing subsystem 553, (b) through the ink printing subsystem 553 over a material platform 540 and out to the laser cutting subsystem 551, and (c) through the laser cutting subsystem 551 and out of the material egress 526 at the laser cutting subsystem 551. In the example CNC / print system 550, the laser cutting subsystem 551 is positioned after the ink printing subsystem 553.In other embodiments, the ink printing subsystem 553 may instead be placed after the laser cutting subsystem 501.

[0417] In some embodiments, (i) the material feeding subassembly 510 guides the material 530 under the laser cutting head 520 along the y-axis, (ii) the laser cutting head 520 moves back and forth along the x-axis via a gantry subassembly, and (iii) one or more optical and / or mechanical components within the laser cutting head 520 control the focal length of the laser beam emitted along the z-axis from the laser cutting head 520 to the surface of the material 530 processed by the laser cutting head 520.

[0418] In other embodiments, (i) the material feeding subassembly 510 guides the material 530 under the laser cutting head 520 along the y-axis, (ii) the laser cutting head 520 moves back and forth along one or both of the x-axis and / or the y-axis via a gantry subassembly, and (iii) one or more optical and / or mechanical components within the laser cutting head 520 control the focal length of the laser beam emitted along the z-axis from the laser cutting head 520 to the surface of the material 530 processed by the laser cutting head 520.

[0419] Examples of gantry subassemblies configured to move a laser cutting head back and forth along one or both of the x-axis and / or y-axis (or any other two axes) that can be used with the CNC / print system 500 (FIG. 5 A) and / or 501 (FIG. 5B) or any of the other CNC / print system embodiments disclosed herein are shown and described in U.S. App. 17 / 511,000, titled “Mechanical System for High Positional Computer Numerically Controlled Applications,” filed on Oct. 21, 2021, published as U.S. Pub. 2023 / 0128807 on Apr. 27, 2023, and currently pending. The entire contents of U.S. App. 17 / 511,000 are incorporated herein by reference.

[0420] FIG. 6 shows an example of a laser cutting module 600 configured to process material received from an ink printing module according to some embodiments.

[0421] Laser cutting module 600 is configured to receive material from an ink printing module (not shown in FIG. 6). The ink printing module could be any type of ink printer now known or later developed, including any type of laser printing module or inkjet printing module. In some embodiments, the ink printing module may be the same as or similar to ink printing subsystem 503 (FIG. 5A) or ink printing subsystem 553 (FIG. 5B). In some example configurations, the laser cutting module 600 is configured to receive material 630 from a high speed laser printer. The material 630 may be any of the types of material disclosed herein. In some embodiments, the material 630 is paper or cardboard.

[0422] In operation, the laser cutting module 600 receives material 630 from the ink printing module and into a laser processing area 602. The laser processing area 602 is enclosed within a housing similar to any of the housings shown and described herein, e.g., housing 102 (FIGS. 1A-D), 202 (FIG. 2A), and / or 502 (FIGS. 5A-B). Some embodiments include one or more cameras 690 positioned within the housing of the laser cutting module 600 and arranged to capture images of the material 630 before, during, and / or after processing via the laser cutting head 620. In some configurations, the one or more cameras 690 can be used to control one or more aspects of processing the material 630 via the laser processing head 620. In some configurations, the laser cutting module 600 includes a galvanometer 621 (sometimes referred to as a galvo) configured to steer laser light emitted by the laser cutting head 620 onto the surface of the material 630 positioned within the laser processing area 602, thereby facilitating processing of the material 630 via the laser cutting head 620.

[0423] Material 630 received from the ink printing module is positioned onto a horizontal panel 604. In some configurations, the horizontal panel 604 implements a vacuum suction that holds the material 630 on the horizontal panel 604 while the material 630 is within the laser processing area 602 of the laser cutting module 600. In some configurations, the vacuum suction keeps the material 630 on the horizontal panel 604 while the material 630 is being processed by the laser cutting head 620. In some embodiments, the horizontal panel 604 includes a plurality of air holes via which air is suctioned to generate the vacuum force that holds the material 630 against the surface of the horizontal panel 604.

[0424] After processing the material 630 via the laser cutting head 620, the horizontal panel 604 pivots about pivot point 606 to move the material 630 onto a stack 608 of processed material. In operation, the horizontal panel 604 pivots about 180 degrees about the pivot point 606. The material 630 is facing upwards when the horizontal panel 604 is in a first position under the laser processing area 602, and the material 630 is facing downwards towards the stack 608 after the horizontal panel 604 pivots about the pivot point 606 to a second position over the stack 608. The horizontal panel 604 continues to apply the vacuum suction to hold the material 630 against the surface of the horizontal panel 604 until the horizontal panel 604 has positioned the material 630 over the stack 608 of processed material. Once the material 630 is positioned over the stack 608, the horizontal panel 604 switches from (i) applying vacuum suction (via the holes in the horizontal panel 604) to hold the material 630 on the surface of the horizontal panel604 to (ii) blowing air (via the holes in the horizontal panel 604) to deposit the material 630 onto the stack 608 of processed material.

[0425] In the example configuration of FIG. 6, the stack 608 of processed material is held in an output tray 610. In some configurations, each time a new piece of processed material is placed onto the stack 608 of processed material, the output tray 610 is lowered by an amount sufficient to accommodate the additional piece of processed material.

[0426] In operation, receiving the material 630 from the ink printing module, holding the material 630 against the surface of the horizontal panel 604 via the vacuum suction while processing the material 630 via the laser processing head 620, and depositing the material 630 onto the stack 608 of processed material in the output tray 610 can happen very quickly. This arrangement can be beneficial when mass processing many items of materials (e.g., pages of paper, cardboard, or other materials) that require both ink printing and laser processing.

[0427] In some embodiments, the horizontal panel 604 may be rotated (or pivoted) over to the right to expose a drawer 612 or similar enclosure. After an object has been placed into the drawer 612, the laser cutting module 600 can process the object via the laser cutting head 620. In some configurations, the one or more cameras 690 are arranged to capture images of the material 630 placed within the drawer 612 before, during, and / or after processing via the laser cutting head 620.VI. AI-Assisted Design Workflows

[0428] The CNC / print systems described in the preceding sections include hardware components for performing laser cutting and ink printing operations on materials. In some embodiments, the CNC / print systems (and / or computing systems configured to control and operate the disclosed CNC / print systems) additionally include software that facilitates the processing of natural language inputs to generate design files containing both printing instructions and cutting instructions. In some embodiments, the software may be implemented as a network-connected program that communicates with remote Al models for design generation. In operation, a CNC / print system executes the printing and cutting instructions to generate a rendered fabrication result as described in further detail in this section.

[0429] FIG. 7 shows a flowchart illustrating an Al-assisted design method 700 for generating print and cut designs from natural language input according to some embodiments.

[0430] Method 700 begins at block 702, which includes determining material parameters. In some embodiments, determining material parameters at block 702 includes determining one or more material parameters for a material to be processed by a CNC / print system, wherein the CNC / print system comprises (i) an ink printing subassembly and (ii) a laser cutting subassembly. The CNC / print system may be the same as or similar to any of the CNC / print systems disclosed herein or any other CNC / print system that has ink printing and laser cutting capabilities. In some embodiments, determining the one or more material parameters comprises receiving one or more user inputs specifying material type, thickness, weight, and surface characteristics. Some embodiments additionally or alternatively include automatically detecting material properties using computer vision algorithms that analyze image data from one or more cameras associated with the CNC / print system (e.g., cameras within the housing of the CNC / Print system). The material parameters may include quantitative properties such as material thickness measured in millimeters, paper weight measured in grams per square meter (gsm), and qualitative properties such as surface texture, coating type, and adhesive backing presence. In some examples, a print server (Section VIII) is configured to utilize these material parameters to determine appropriate cutting parameters. For example, lighter materials such as 20 lb paper (approximately 75 gsm) require lower laser power and / or shorter dwell times compared to heavier materials such as 110 lb cardstock (approximately 300 gsm) which require comparatively higher laser power and / or longer dwell times to achieve complete cuts. In some examples, the material property processing includes determining material brittleness characteristics that may, in some instances, influence perforation parameter selection. For example, more brittle materials may require larger uncut segment spacing to prevent premature tearing during material handling.

[0431] In some examples, determining the material parameters at block 702 includes at least one of (i) manually configuring material parameters via user input and / or (ii) automatically determining material parameters using one or more computer vision algorithms that analyze image data from one or more cameras associated with the CNC / print system to identify material characteristics. In some embodiments, the material parameters determined at block 702 include one or more (or all) of a surface texture, color, thickness indicators, barcode identifiers, manufacturer markings, or spectral properties of the materials.

[0432] For example, in some embodiments, the material parameters may be received from a user via a graphical user interface associated with the CNC / print system. For instance, theuser may enter material type information such as “20 lb Sticker Paper” (see, e.g., FIGs 8A-8F) or “80 lb Cardstock” (see, e.g., FIGs 10A-10E) via the graphical user interface. In some embodiments, the automatic material detection employs computer vision algorithms to identify material characteristics including but not limited to surface texture, color, thickness indicators, barcode or QR code identifiers, manufacturer markings, or spectral properties captured through specialized sensors. In some examples, the one or more cameras may be mounted inside the CNC / print system or may be external devices such as mobile phones or tablets associated with the CNC / print system. In some examples, the system maintains a database of material profiles that includes, for each of a plurality of different material types, one or more of attributes associated with that material type, e.g., printing parameters, cutting depths for kiss-cutting versus through-cutting, ink absorption characteristics, and other operational attributes of the material.

[0433] Determining the material parameters at this block 702 can be advantageous because it enables the CNC / print system to automatically configure appropriate processing parameters for both the ink printing subassembly and / or the laser cutting subassembly based on the specific characteristics of the material being processed. For example, when CNC / print system determines that the material is “20 lb Sticker Paper” versus “80 lb Cardstock,” the CNC / print system can adjust cutting depths for kiss-cutting versus through-cutting operations, modify ink print application parameters based on material absorption characteristics to prevent bleeding or smudging, and optimize printing parameters such as ink density and curing time based on the material’s surface properties. Additionally, the automatic material detection using computer vision algorithms to identify surface texture, color, thickness indicators, barcode identifiers, or spectral properties can reduce the potential for user error in material identification, which could otherwise result in inappropriate cutting depths that either fail to cut through the material completely or cut too deeply and damage the backing material. This material parameter determination also enables the system to access material-specific profiles from its database that include pre-tested printing parameters, cutting strategies, and design modifications that have been proven to work effectively with each material type, thereby reducing trial-and-error and material waste.

[0434] Block 704 includes determining one or more CNC / print system machine parameters. In some embodiments, determining the one or more machine parameters comprises one of (i) selecting the CNC / print system from a list of available machines based on user input,or (ii) automatically determining machine parameters based on user identification, previously configured machine settings, and / or machine capabilities. In some instances, the machine capabilities include functional capabilities and / or limitations such as maximum cutting depth, available ink colors, print resolution, cutting precision, multi-pass capabilities, and material handling constraints. In some embodiments, the maximum cutting depth and cutting precision may be based on the configuration and / or capabilities of the laser cutting head. Similarly, the available ink colors and / or print resolution may be based on the configuration of the ink printing head, including the type(s) of ink available for use (e.g., installed in) the ink printing head. Multi-pass capabilities and handling constraints may include, for example, a maximum length, width, and / or height of the material to be processed, limitations on the type (or types) of materials that that machine can (or cannot) process, areas on a piece of material where the CNC / print system may be able to print only, cut only, and / or both print and cut, all of which may which may be based on the size and configuration of the CNC / print system and / or arrangement of the ink printing head and / or laser cutting head. In some embodiments, the design parameters can be based at least in part on the CNC / print system’s capabilities, such as simplifying cut paths for machines with lower precision or adjusting color profiles based on the type and / or color of ink that the CNC / print system is configured to apply to materials.

[0435] Determining the one or more CNC / Print system machine parameters at block 704 is advantageous because it enables aspects of the design generation and fabrication instructions (e.g., Block 708) to the specific capabilities and limitations of the available CNC / print system, thereby improving the likelihood of compatibility between the Al-generated design and the actual CNC / print system that will execute the instructions to generate the fabrication result. For example, if a particular CNC / print system has lower cutting precision capabilities, a design generated for implementation by that particular CNC / print system can incorporate simplified cutting paths to accommodate the cutting precision achievable by that particular CNC / print system (or at least achievable by the laser cutting subassembly thereof). Similarly, if a particular CNC / print system has the capability to print certain colors or color combinations, a design generated for implementation by that CNC / print system can incorporate colors and / or color combinations that are supported by that CNC / print system (or at least achievable by the ink printing subassembly thereof).

[0436] Block 706 includes receiving a natural language design description of a desired fabrication result. In some embodiments, receiving the natural language description of the desired fabrication result includes receiving input via at least one of one or more input modalities. For example, in some instances, the natural language description of the desired fabrication result may be in the form of at least one of a text input, a voice input, an image upload, and / or a sketch input.

[0437] For instance, as illustrated in FIG. 8A, the graphical user interface may present a text input field with the prompt “Step 1 : Type anything you can imagine” where a user can enter descriptions such as “Seattle themed sticker featuring the Seattle Space Needle, Seattle ferry, and Mt. Rainier.” In some examples, the Al engine employs multiple specialized models including natural language processing for text interpretation, image recognition for uploaded references, and generative models for design creation.

[0438] Block 708 includes generating a print and cut design based on the natural language description of the desired fabrication result. In some embodiments, using the generative Al model to generate the print and cut design includes analyzing the natural language design description to identify contextual cues about the desired fabrication result. For example, if a sticker design is desired, the contextual cues may include text explicitly indicating a sticker is desired or text implicitly suggesting a sticker. Additionally and / or alternatively, contextual cues may include, for example, the one or more material parameters indicating sticker material and / or the one or more machine parameters indicating the CNC / print system is configured to create print and cut stickers. In this example, the contextual cues include prompt text explicitly indicating sticker is desired (“...sticker...”), prompt text implicitly suggesting sticker use (“...to put on my water bottle...” such as shown in block 802 (FIG. 8 A)) material currently selected and / or determined is a sticker material (e.g., “sticker paper”), and / or machine configured to print and cut stickers.

[0439] In some examples, generating the print and cut design includes generating design elements such as a border indicating an outer edge (e g., geometric shapes, organic cures, complex die-cut patterns), a background color or gradient that complements one or more design elements, white or colored backing generation for transparent materials, bleed areas that extend beyond cut lines to provide clean edges. Some examples may also include automatically generating white or colored backing for transparent materials to enhance visibility and designcontrast. Some examples may additionally include automatically determining a cutting strategy based on the one or more material parameters and intended use. For example, a cutting strategy may include (i) kiss-cutting through a sticker layer while leaving backing intact, (ii) through- cutting for standalone items, and / or (iii) multi-layer cutting strategies wherein different depths are used for different design elements. Some embodiments may include automatically determining an appropriate cutting strategy based on material properties and intended use. For removable stickers, kiss-cutting may be selected to cut through the sticker layer while leaving the backing intact. For standalone stickers, through-cutting may be implemented instead. The system may also implement multi-layer cutting strategies where different depths are used for different design elements, such as scoring fold lines within a design while cutting perimeters around a design.

[0440] In some embodiments, generating the print and cut design additionally includes analyzing the generated print and cut design using one or more artificial intelligence algorithms to identify potential production issues with the initially-generated print and cut design.Examples of potential production issues include thin protruding elements that may tear during removal, small interior cuts that may be difficult for the CNC / print system to make and / or the user to detach, and / or color combinations that may not reproduce well on the material to be processed by the CNC / print system. After identifying one or more potential production issues with the initially-generated print and cut design, some embodiments include (i) generating a revised print and cut design that addresses the one or more potential production issues and / or (ii) identifying the potential production issues with the initially-generated print and cut design to the user via the graphical user interface along with suggested modifications and / or presenting alternative print and cut designs that address the identified potential production issues while still complying with the desired fabrication result.

[0441] In some embodiments, using the generative Al model to generate the print and cut design further comprises accessing template-based cutting patterns for common applications including business cards, labels, tickets with tear-off stubs, or photo prints with standard sizes. Some such embodiments may additionally include selecting an appropriate template based on the natural language design description and the determined material parameters.

[0442] Block 710 includes placing the print and cut design on the material. In some embodiments, block 710 includes displaying the placement of the print and cut design on thematerial comprises one or more of (i) implementing nesting algorithms that arrange multiple designs on the material to improve material usage efficiency, (ii) providing real-time feedback showing material utilization percentage, and / or (iii) suggesting additional copies or complementary designs to make efficient use of the material. For example, if a user wishes to produce multiple stickers on a single sheet of sticker paper, the nesting algorithms in some embodiments can improve material usage efficiency by arranging the multiple stickers efficiently onto the sticker paper while also maintaining appropriate spacing for clean cutting. In examples where the material to be processed is wood, the nesting algorithms may additionally consider the grain direction of the wood and defects in the material (e.g., knots or undesirable patterning). In some examples, the nesting algorithms may also consider appropriate spacing between adjacent designs placed on the material to maintain sufficient space between designs for clean cutting. In some examples, the nesting algorithms may avoid defects detected by the camera system within the CNC / print system. In some embodiments, the system may be configured to provide real-time feedback showing material utilization percentage and suggesting additional copies or complementary designs that may improve over material usage efficiency.

[0443] In some embodiments, the print and cut design may include default cut / score lines for cut and / or score (e.g., kiss-cut) operations along the outer edges of the design. Some embodiments may include automatically determining an appropriate cutting strategy based on material properties and intended use. For example, for removable stickers, kiss-cutting may be selected to cut through the sticker layer while leaving the backing of the sticker paper intact. For standalone stickers, through-cutting may be selected. In some examples, the CNC / print system may also implement multi-layer cutting strategies where different depths are used for different design elements, such as scoring fold lines while cutting perimeters.

[0444] In some embodiments, the graphical user interface may display configuration and operation controls that enable a user to further manipulate printing and cutting parameters for generating the fabrication result. For example, the graphical user interface in some embodiments provides control over various aspects of the design placement and fabrication parameters. For instance, as illustrated in Figures 8E and 8F, the user interface may provide controls for one or more (or all) of (i) modifying the outer edge cut or score functionality with precise depth control, (ii) modifying printing colors, (iii) changing the outer edge shape, including options for standard shapes, custom paths, or Al-generated organic borders, and / or (iv) adding additional outer edgessuch as cutting the outermost edge around the design while scoring an inner decorative border. In some examples, the user interface may additionally provide controls for modifying one or more edges around the design with variable offsets that can follow the design contour or maintain uniform spacing, adding perforation patterns for easy removal sections, implementing multi-pass strategies for thick materials, and / or creating laminated designs with protective overlays.

[0445] In some embodiments, the CNC / print system may include predictive modeling that simulates the final result, showing, via the graphical user interface, one or more (or all) of (i) how different materials will appear with the selected inks, (ii) how cuts will look with various depths, and (iii) potential areas where weeding or removal might be challenging. Some such embodiments may use machine learning models trained on previous job outcomes to provide predictions about the fabrication process and final result quality.

[0446] Once the design and its placement have been “finalized” for rendering, some embodiments include generating rendering instructions based on the finalized print and cut design and the corresponding placement of the design on the material. In operation, the rendering instructions include both (i) ink printing instructions and (ii) laser cutting instructions.

[0447] In some embodiments, generating the rendering instructions may be performed in response to receiving a “print” (or similar) command from the user. In some embodiments, generating rendering instructions based on the print and cut design comprises organizing / planning an instruction sequence considering factors including ink drying time before cutting, planned cutting order to prevent (or avoid) material shifting, and environmental conditions affecting material behavior. When generating the rendering instructions based on the print and cut design, some embodiments include generating multiple file formats for implantation / execution by different machine types while maintaining design fidelity.

[0448] Generating the rendering instructions for execution by the CNC / print system after finalizing the print and cut design and its placement is advantageous because it enables generation of the rendering instructions as the final step before actually executing the rendering instructions, thereby ensuring that all design parameters, material properties, and placement configurations have been finalized before committing to the fabrication process. This approach allows the CNC / print system to incorporate any last-minute adjustments or modifications made during the design placement phase so that the rendering instructions reflect the final and complete design specifications before actual rendering.

[0449] Finally, Block 712 includes rendering the design on material. In operation, block 712 includes generating a rendered fabrication result by executing the rendering instructions. In some embodiments, causing the CNC / print system to generate the rendered fabrication result by executing the rendering instructions includes (i) using the ink printing subassembly to apply ink to the material according to the printing instructions and (ii) using the laser cutting subassembly to cut the material according to the cutting instructions. Some scenarios may include executing the printing instructions to print the printable aspects of the fabrication result, and then executing the cutting instructions to cut the cutting aspects of the fabrication result. Other scenarios may include cutting and then printing. Still further scenarios may include performing printing operations and cutting operations concurrently, either at the same location on the surface of the material or at different locations on the surface of the material.VII. Example User Interfaces for AI-Assisted Design

[0450] FIG. 8A shows an example user interface 800 for entering natural language design descriptions and selecting art styles for printing with a CNC / print system according to some embodiments.

[0451] User interface 800 includes a text box 802 arranged to allow a user to input a natural language design description of a desired fabrication result. In operation, text box 802 enables the user interface to receive the natural language design description of the desired fabrication result in a manner similar to method block 706 (FIG. 7). For text box 802, user interface 800 invites a user to “Type anything you can imagine.” In the example shown in FIG. 8A, a user has entered “Seattle themed sticker featuring the Seattle Space Needle, Seattle ferry, and Mt. Rainier to put on my water bottle.”

[0452] User interface 800 also includes region 804, which allows a user to “Choose an art style optimized for printing on Glowforge” and includes several art styles, including but not limited to Color Sticker, Icon, Silhouette, Sticker, Charcoal Drawing, Watercolor, Grownup Coloring Book, Black & White Photograph, Super Cute, T-Shirt, Create-a-Card, and Pendant. Each of these art styles utilizes one or both printing and / or cutting / engraving features implemented by a CNC / print system. For example, the “Color Sticker” art style uses printing and cutting features. The Icon, Silhouette, Create-a-Card, etc. art styles use cutting features,including cutting, scoring, and engraving. In the example shown in FIG. 8A, a user has selected the “Color Sticker” art style in region 804.

[0453] User interface 800 also includes information about the material to be processed by the CNC / print system in region 808. In the example shown in FIG. 8A, the material shown in region 808 is “20 lb Sticker Paper.” However, in other examples, the material could be any other suitable material that can be processed by the CNC / print system, including but not limited to any of the materials disclosed and described elsewhere herein.

[0454] User interface 800 also includes “Make Magic!” button 806. In operation, after detecting a user activation of the “Make Magic!” button 806, information about the desired fabrication result (i.e., the text from box 802 and the selection from region 804, the material type indicator in region 808) perhaps along with additional information about the CNC / print system is provided to one or more generative Al models. In operation, the one or more generative Al models generate a print and cut design based on the information about the desired fabrication result (including the natural language description in box 802).

[0455] FIG. 8B shows a generated design 810 within the user interface 800 of FIG. 8 A based the natural language description of the desired fabrication result along with options to use the generated design or generate additional variations according to some embodiments.

[0456] Field 812 includes the natural language description of the desired fabrication result, which in this example is a combination of the text from box 802 (FIG. 8A) and the art style selected from region 804 (FIG. 8A). Field 812 also includes an “Edit” block 814 which, when activated, enables a user to edit the natural language description of the desired fabrication result.

[0457] The generated design 810 is consistent with the natural language description of the desired fabrication result. In particular, the generated design 810 includes colored depictions of the Space Needle 820, the Seattle ferry 822, and Mt. Rainier 824 received from the user via text box 802 (FIG. 8A) and reproduced in field 812, and the size of the design is suitable for the “Color Sticker style” art style selection received from the user via region 804 (FIG. 8A) and reproduced in field 812.

[0458] Adjacent to the generated design 810, the user interface 800 also includes “Use this image” button 816 that, when activated, causes the generated design 810 to be used for generating rendering instructions for execution by a CNC / print system. The user interface 800also includes “Make more Magic!” button 818 that, when activated, returns user interface 800 back to the screen depicted in FIG. 8A where a user can start over with a new natural language description and / or new art style.

[0459] FIG. 8C shows the generated design 810 from FIG. 8B with a cut outline 826 and a score outline 828 added around the generated design 810. Recall that region 808 indicates that the material is “20 lb Sticker Paper.” In FIG. 8C, the cut outline 826 indicates where the laser cutter will cut entirely through the sticker paper so that the sticker can be removed from the sticker paper, and the score outline 828 indicates where the laser cutter will cut through the top layer (the sticky layer) of the sticker paper but not all the way through the sticker paper so that the sticker can be peeled away from the backing of the sticker paper.

[0460] FIG. 8D shows the generated design 810 placed on the sticker material within the user interface 800 according to some embodiments.

[0461] By showing how the generated design 810 will be placed onto the material (which is 20 lb Sticker Paper in this example), the user interface 800 allows the user to see where on the physical material that the design will be fabricated by the CNC / print system. In this view, the user can see how close the cut outline will be to the edge(s) of the material.

[0462] Activating region 834 enables aspects of the generated design 810 to be adjusted. For example, controls in box 836 enable the generated design 810 to be moved to different positions on the material, resized to be smaller or larger, text within the generated design can be edited, and so on. Similarly, activating region 830 enables the score outline 828 to be resized, and activating region 832 enables the cut outline 826 to be resized.

[0463] FIG. 8E shows a close up view of the top left comer of the user interface 800 screen in FIG. 8D, and FIG. 8F shows a close up view of the right side of the user interface 800 screen in FIG. 8D when region 832 on the top left side of the user interface 800 screen of FIG. 8D is selected. When region 832 (for “Cut”) is selected in the top left portion of the user interface 800 depicted in FIG. 8E, aspects of the cut outline 826 (FIGs. 8C-D) can be edited via the controls on the right side of the user interface 800 depicted in FIG. 8F.

[0464] When icon 838 is activated on the right side of the user interface 800 (FIG. 8F), an options window 840 is displayed to the user for editing one or more aspects of the “Patterned Line” for the cut. Region 842 of options window 840 enables the user to select the type of line (e.g., “Perforated line”) to be cut, region 844 of options window 840 enables the user to selectthe width of the line to be cut (e.g., “30 mm”), region 846 of options window 840 enables the user to select the gap width of the line to be cut (e.g., “0.1 mm”), and region 848 of options window 840 enables the user to select the offset of the line to be cut (e.g., “4 mm”).

[0465] FIG. 9A shows a front view of an example CNC / print system 900 implementing the generated design 906 from FIGS. 8A-F onto sticker paper material. The CNC / print system 900 includes an ink printing head and a laser cutting head. The CNC / print system 900 may be the same as or similar to any of the CNC / print system embodiments described herein.

[0466] In FIG. 9A, the CNC / print system 900 has already printed the generated design 906 onto the sticker paper 902 via the ink printing head because the generated design 906 is visible on the surface of the sticker paper 902 protruding from the front entrance 904 of the CNC / print system 900. After having printed the generated design 906 onto the sticker paper, the CNC / print system 900 next performs cutting and scoring procedures via the laser cutting head to both (i) cut a perforated line that enables the generated design 906 to be removed from the sticker paper 902 and (ii) score a border around the generated design 906 that enables the generated design 906 to be removed from the backing of the sticker paper 902. Cutting the perforated line is sometimes referred to as a “cut-through” and scoring the border around the generated design 906 is sometimes referred to as a “kiss-cut.”

[0467] In some embodiments, the CNC / print system 900 implements a sequential cutting strategy for sticker fabrication wherein the CNC / print system 900 first creates the kiss-cut operation to create the kiss-cut (e.g., 828 (FIG. 8C)) around the printed design, followed by the cut-through operation to create the cut-through (e.g., 826 (FIG. 8C)) operation that surrounds the kiss-cut boundary. This sequential approach ensures that the inner kiss-cut boundary (e.g., 828) is precisely positioned relative to the printed design before the outer cut-through boundary (e.g., 826) is created, maintaining accurate registration between the printed content and both cutting operations. The sequential cutting process in some examples may include intermediate positioning adjustments between the kiss-cut and cut-through operations to account for any material movement or thermal effects from the initial cutting operation.

[0468] FIG. 9B shows the front view of the example CNC / print system 900 of FIG. 9A while the CNC / print system 900 is performing the cutting and scoring procedures on the sticker paper 902 to produce the custom-created sticker with the generated design 906. The glow emanating from the front entrance 904 of the CNC / print system 900 in area 908 is fromoperation of the laser cutting head of the CNC / print system 900 during the cutting and scoring procedures.

[0469] FIG. 9C shows the front view of the example CNC / print system 900 while the example CNC / print system is outputting the sticker paper 902 after printing, scoring, and cutting the sticker paper 902 to fabricate the custom-created sticker 910 with the generated design 906.

[0470] In operation, the CNC / print system 900 is outputting the sticker paper 902 from the front entrance 904 of the CNC / print system 900. The sticker paper 902 includes the custom- created sticker 910. The custom-created sticker 910 has a sticker portion 910a bounded by score line 912 and a backing portion 910b bounded by cut line 914.

[0471] FIG. 9D shows a user removing the custom-created sticker 910 from the sticker paper 902. In operation, the custom-created sticker 910 is removed from the sticker paper 902 along cut line 914.

[0472] FIG. 9E shows the user removing the sticker portion 910a from the backing portion 910b. The sticker portion 910a is removed from the backing portion 910b via score line 912 (FIG. 9C).

[0473] FIG. 9F shows the user applying the sticker portion 910a onto a mug 916 after the sticker portion 910a has been removed from the backing portion 910b.

[0474] FIG. 10A shows an example user interface 1000 for entering natural language design descriptions and selecting art styles for printing with a CNC / print system according to some embodiments.

[0475] User interface 1000 includes a text box 1002 arranged to allow a user to input a natural language design description of a desired fabrication result. In operation, text box 1002 enables the user interface to receive the natural language design description of the desired fabrication result in a manner similar to method block 706 (FIG. 7). For text box 1002, user interface 1000 invites a user to “Type anything you can imagine.” In the example shown in FIG. 10A, a user has entered “rabbit surfing with sunset.”

[0476] User interface 1000 also includes region 1004, which allows a user to “Choose an art style optimized for printing on Glowforge” and includes several art styles, including but not limited to Modern Logo, Icon, Silhouette, Create-a-Card, and Pendant. In the example shown in FIG. 10A, the set of art styles has been filtered by “Great for Cutting” and a user has selected the “Create-a-Card” art style in region 1004.

[0477] User interface 1000 also includes information about the material to be processed by the CNC / print system in region 1008. In the example shown in FIG. 8 A, the material shown in region 1008 is “80 lb Cardstock.” However, in other examples, the material could be any other suitable material that can be processed by the CNC / print system, including but not limited to any of the materials disclosed and described elsewhere herein

[0478] User interface 1000 also includes “Make Magic!” button 1006. In operation, after detecting a user activation of the “Make Magic!” button 1006, information about the desired fabrication result (i.e., the text from box 1002 and the selection from region 1004, the material type indicator in region 1008) perhaps along with additional information about the CNC / print system indicated in region 1010 is provided to one or more generative Al models. In operation, the one or more generative Al models generate a print and cut design based on the information about the desired fabrication result (including the natural language description in box 1002).

[0479] FIG. 10B shows a generated design 1012 within the user interface 1000 of FIG. 10A based the natural language description of the desired fabrication result along with options to use the generated design or generate additional variations according to some embodiments.

[0480] Field 1014 includes the natural language description of the desired fabrication result, which in this example is a combination of the text from box 1002 (FIG. 10A) and the art style selected from region 1004 (FIG. 10 A). Field 1014 also includes an “Edit” block 1016 which, when activated, enables a user to edit the natural language description of the desired fabrication result.

[0481] The generated design 1012 is consistent with the natural language description of the desired fabrication result. In the example shown in FIG. 10B, generated design 1012 is one of three designs selectable by a user in region 1018. Each of designs in region 1018 (including generated design 1012) includes a depiction of a rabbit riding a surfboard, and the size of the design is suitable for the “Create-a-Card” art style selection received from the user via region 1004 (FIG. 10A) and reproduced in field 1014.

[0482] Adjacent to the generated design 1012, the user interface 1000 also includes “Use this image” button 1020 that, when activated, causes the generated design 1012 to be used for generating rendering instructions for execution by a CNC / print system. The user interface 1000 also includes “Make more Magic!” button 1022 that, when activated, returns user interface 1000back to the screen depicted in FIG. 10A where a user can start over with a new natural language description and / or new art style.

[0483] FIG. 10C shows a sub-window 1024 of the user interface 1000 depicting the generated design 1012 that was selected by the user in FIG. 10B along with a “Use image as-is” button 1026 and an “Adjust artwork” button 1028.

[0484] When activated, the “Use image as-is” button 1026 causes the generated design 1012 to be used in its current form for the next stage of creating the card. The “Adjust artwork” button 1028, when activated, enables the user to adjust one or more aspects of generated design 1012 before proceeding to the next stage of creating the card.

[0485] FIG. 10D shows an example editing window 1030 of the user interface 1000 via which a user can edit one or more aspects of the generated design 1012. The editing window 1030 in an example editing window that is displayed when the “Adjust artwork” button 1028 of FIG. 10C is activated. In operation, activating the “Crop” button 1032 enables the user to crop the generated design 1012. Similarly, activating the “Edit” button 1034 enables the user to edit the generated design 1012 with drawing markups via the drawing options shown in box 1036. In the example shown in FIG. 10D, the drawing options include “white” markups, “black” markups, and “line width” (indicated as “Medium”).

[0486] In operation, the white markup option in box 1036 can be used to apply white marks on the black portions of the generated design 1012 and / or to erase black markups that have been applied to the white portions of the generated design 1012, and the black markup option in box 1036 can be used to apply black marks on the white portions of the generated design 1012 and / or to erase white markups that have been applied to the black portions of the generated design 1012. In the example illustrated in FIG. 10D, a user has added an eye 1038 to the rabbit on the surfboard in the generated design 1012.

[0487] After editing the generated design 1012, a user can select the “Apply Changes” button 1040 or the “Cancel” button 1042. In operation, activation of the “Apply Changes” button 1040 causes the changes made to the generated design 1012 in the editing window 1030 to be added to the generated design 1012 for use in the next stages of the creating the card, whereas activation of the “Cancel” button 1042 discards changes made to the generated design 1012 in the editing window 1030.

[0488] FIG. 10E shows the generated design 1012 incorporated as a card design (e g., based on the “Create-a-Card” art style selection) within the user interface 1044 for editing the layout and content of the card to be fabricated by the CNC / print system.

[0489] User interface 1044 includes, among other features, an editing sidebar 1046 with several editing options. One editing option is an option to add to text to the card. For example, activation of the “TT” button 1048 launches text editing window 1050, which includes, text options such as the (i) the content of the text, (ii) the typeface of the text, (iii) the “weight” of the text (e.g., regular, bold, italic), (iv) the size of the text, (v) the alignment of the text (e.g., left, center, right), (vi) the spacing of the text (i.e., the spacing between adjacent letters), and (v) the style of the text.

[0490] In the example depicted in FIG. 10E, the user has added design element 1052 containing text to the card 1054 right below the generated design 1012. In particular, design element 1052 includes a left-aligned text block stating “Happy Father’s Day” in 33 point, regular weight “Big Shoulders Stencil Text” typeface (sometimes called font).

[0491] After editing the card content and layout in user interface 1044, the final card layout is used to create rendering instructions for use by the CNC / print system to generate the final rendered fabrication result.VIII. Print Server / Print Options Features

[0492] The CNC / print systems described in the preceding sections are configured to work with Al-assisted design tools that implement workflows and user interfaces for creating combined print and cut designs. In some embodiments, the CNC / print system additionally includes corresponding print server functionality that enables users to define cutting operations with a print interface configured to operate with the disclosed CNC / print systems.

[0493] Some traditional printer drivers enable a user to select features for a print job such as, for example, stapling, hole-punch, folding, and double-sided printing. These print driver interfaces also often include page setup functionality for defining page size (e.g., A4, 8 1 / 2 x 11, legal, etc.) and orientation (e.g., landscape and portrait). However, these conventional features are generally limited to functionality based on the paper size and the capabilities of basic ink printers. The features of traditional ink printer drivers cannot be customized by the user for the specific design content being printed on the paper.

[0494] Therefore, some embodiments additionally include new print server application software that can be used with the CNC / print system for implementing aspects of both the printing and cutting features. In some embodiments, the print server application is implemented as a virtual printer driver that intercepts standard print and / or cut jobs and enhances those print and / or cut jobs with cutting instructions for implementation by the CNC / print system. In other embodiments, the print server application is implemented as a cloud-based service that (i) receives a fabrication job from a computing device (e.g., a computing device running the user interfaces described with reference to Figures 7, 8A-F, or 10A-E), (ii) processes the fabrication job to generate print and / or cut instructions and / or modify print and / or cut instructions, and (iii) send the printing and / or cutting instructions to the CNC / print system for implementation. In still other embodiments, the print server application is implemented as a local software application running on a computing device configured to control one or more aspects of the CNC / print system.

[0495] In some print server application embodiments, users can define specific areas on their printed documents where cutting operations should be performed. By enabling a user to specify cutting functions to be performed on a document, the print server application avoids scenarios where a user has to (i) print a document (e.g., a sheet of name tags for a business meeting) and (ii) manually cut the document (e.g., cut out the individual name tags) after printing with a manual cutting tool. Instead, the new print server application enables the CNC / print system to both print and cut a document. Example cut regions include outlining or surrounding objects (e.g., a nametag) with an adjustable margin (e.g., millimeters) from the objects (e.g., adjacent nametags). Cut regions may also include standard shapes such as rectangular (e.g., sharp or rounded corners), circular, bubble, or other geometric forms.

[0496] In some embodiments, cut regions may include horizontal or vertical cuts at particular points in the material (1 / 2 page, 1 / 3 page, 1” margin, etc.) and user-definable boundaries. Additional cut region capabilities may include automatic object detection that identifies discrete design elements (images, text blocks, tables) and suggests appropriate cutting boundaries to accommodate the design elements.

[0497] In some embodiments, the print server application enables template-based cutting for common applications such as business cards (10-up), labels (various standard formats), tickets with tear-off stubs, or photo prints with standard sizes. The print server application canalso implement dynamic cut patterns that adapt based on content, such as following the contour of irregular images or other irregular design elements, creating puzzle-piece connections between elements, or generating decorative borders that complement the printed design. In some embodiments, the set of cutting patterns comprises predefined templates stored in a database, wherein each template includes specific cut line geometries optimized for particular applications. For example, business card templates may include standard 3.5” x 2” rectangular cut patterns with optional rounded corner variations, while label templates may include circular, oval, or custom die-cut shapes with appropriate bleed margins. The print server application implements pattern selection algorithms that analyze the print content to identify content type indicators such as text layout, image positioning, and document dimensions, and automatically selects an appropriate cutting pattern from the database based on the identified content characteristics and the determined material properties. In some examples, the pattern selection process considers material thickness when selecting between kiss-cut patterns for adhesive-backed materials versus through-cut patterns for standalone items. Some embodiments also include adjusting cut line spacing and margin requirements based on material brittleness and cutting precision capabilities of the laser cutting subassembly.

[0498] In some embodiments, the print server application may additionally or alternatively implement multi-level cutting with different depths for score lines, perforations, and through-cuts within the same rendering job. Some embodiments may include QR code or barcode triggered cutting where the print server application extracts encoded cutting instructions embedded in the QR code and / or barcode. The print server application in some examples may also implement instructions for generating fold lines to create 3D objects, greeting cards, or origami patterns with precise valley and mountain fold indicators.

[0499] To facilitate material cutting in the CNC / print system, some print server application embodiments also translate cut regions into finely perforated cuts such that the material can still be fed through the CNC / print system after cutting. In some examples, parameters such as perforation size and separation can be modified depending on the material, application, and user preference. In some embodiments, the finely perforated cuts comprise a series of cut segments separated by uncut segments, where typical cut segment lengths range from about 1 mm to about 5 mm and uncut segment spacing ranges from about 0.2 mm to about 2 mm. The specific perforation parameters are determined based on material properties, withlighter materials such as 20 lb paper utilizing shorter cut segments (approximately 1 -2 mm) and smaller uncut spacing (approximately 0.2-0.5 mm) to maintain material integrity during feed- through, while heavier materials such as 80 lb cardstock or photo paper utilize longer cut segments (approximately 3-5 mm) and larger uncut spacing (approximately 1-2 mm) to ensure clean separation while maintaining sufficient connection strength. In some examples, the perforation parameters are automatically adjusted based on detected material brittleness, with more brittle materials receiving increased uncut segment spacing to prevent premature tearing during material handling. The perforated cuts allow the material to remain connected during processing by the CNC / print system while enabling clean separation of cut pieces after processing is complete.

[0500] The print server application in some embodiments may additionally implement intelligent perforation strategies including adapting perforation density to increase connection strength in areas that may be prone to tearing during feed-through of the material into and out of the CNC / print system. Variable perforation patterns implemented by the print server application in some examples may include micro-tabs at corners for stability, continuous perforations along straight edges, and / or reinforced connections at stress points.

[0501] In some embodiments that implement intelligent perforation strategies, the print server application implements a step-by-step processing approach where user-defined cut regions are first analyzed to identify geometric boundaries, then translated into executable cut lines using material-specific algorithms. For example, when processing a business card layout on 80 lb cardstock, the print server may determine that a rectangular cut region requires cut segments of 4 mm length with uncut segments of 1.5 mm spacing to maintain material integrity during processing while enabling clean separation. In contrast, when processing the same layout on 20 lb paper, the algorithm may select cut segments of 2 mm length with uncut segments of 0.5 mm spacing to prevent tearing of the lighter material. The print server application may implement decision trees that automatically select between scoring operations (partial depth cuts of approximately 25-50% material thickness), kiss-cutting operations (cuts through top layer only), and through-cutting operations (complete material penetration) based on material thickness thresholds. For example, materials under 0.2 mm thickness may default to through-cutting, materials between 0.2-1.0 mm thickness may use kiss-cutting for adhesive-backed substrates,and materials over 1 .0 mm thickness may employ scoring for fold lines combined with through- cutting for separation edges.

[0502] In some embodiments, the print server application maintains (or is configured to communicate with a database or other suitable storage that maintains) material -specific perforation profiles with parameters optimized for different types of materials, such as different types of paper, different paper weights, cardstock, photo paper, or specialty materials. The print server application in some examples may also enable implementation of progressive cutting modes where initial passes create light scores followed by deeper perforations, allowing for clean separation while also allowing the material to pass through CNC / print system feed systems (see, e.g., FIGs. 2A-B, 4A-B, and 5A-B). In some embodiments, the material-specific perforation profiles include minimum and maximum perforation parameter thresholds that maintain material integrity during processing while ensuring reliable separation after processing. The perforation profiles may specify cut segment lengths ranging from approximately 1 mm to 5 mm and uncut segment spacing ranging from approximately 0.2 mm to 2 mm, as described herein. The perforation profiles may include threshold determinations for cutting strategy selection based on material thickness, where thinner materials may utilize smaller perforation parameters to prevent tearing, while thicker materials may utilize larger perforation parameters to ensure adequate separation force can be applied during manual removal.

[0503] The user interface for the print and cut functionality in some instances may include a preview pane showing the document with overlay visualization of cut lines, differentiated by color or line style for cuts, scores, and perforations similar that illustrated in FIGs. 8B-C. In some embodiments, the user interface also includes interactive handles for adjusting cut regions directly on the preview with snap-to-grid and alignment guides.

[0504] In some embodiments, the user interface also includes a layers panel for organizing printed content and cut operations, thereby allowing users to toggle visibility and adjust stacking order of design elements. The user interface in some instances may also include a preset management feature that allows users to save and share custom cut configurations for repeated use. In some examples, the user interface may also include an advanced settings panel that allows for numeric input for precise measurements, cut depth control, and perforation parameters.

[0505] In some embodiments, the print server application also supports plugin systems for third-party developers to create custom cutting patterns or to integrate with specific applications. The print server application in some examples may also include job queuing with cut complexity analysis to optimize machine utilization and estimate completion times.

[0506] Some embodiments of the print server application may also include collaboration features where, e.g., cut templates can be shared among friends, between instructors and students, within work teams, or across organizations. In some examples, the print server application may also implement version control for cut patterns, thereby allowing iteration and rollback of design changes to the printing and cutting instructions for a specific design. In some examples, API interfaces for the print server application may enable programmatic access for automation and integration with design software, web applications, or production management systems.

[0507] In some examples, the print server application may also implement mixed-mode processing where cutting instructions are implemented for some pages or pieces of material while printing instructions are implemented for other pages or pieces of material. In some instances, cut-only and / or print-only pages (or pieces) are managed by the print server application via page range selections (for pages) or piece count selections (for pieces of material). The print server application in some examples may include intelligent margin preservation that automatically adjusts cut lines to maintain printer-required margins while maximizing usable area of the paper, cardstock, or other material processed by the CNC / print system.

[0508] Some embodiments of the print server application may additionally include bleed management for edge-to-edge design, which in some embodiments may include calculating appropriate oversizing and cut registration to help achieve high-quality cutting and printing results.

[0509] The print server application in some examples may also implement multi-pass coordination where the print server application manages separate print and cut operations with automatic alignment verification.

[0510] Some print server application embodiments additionally include error handling and recovery mechanisms for detecting potential issues, including but not limited to (i) cutsand / or prints intersecting critical content or areas on the material and / or (ii) cuts and / or prints exceeding material boundaries.

[0511] In some embodiments, the print server application also includes analytics and reporting features that track material usage, cut pattern popularity, and job success rates. In some instances, data from the analytics and reporting features is used to improve system performance, including improving designs as well as improving CNC / print system operating parameters.

[0512] Some print server application embodiments also include security and access control features, such as user-level permissions controlling access to cutting features based on training or authorization levels.VI. Other Examples

[0513] The following section describes several examples. The examples (and features thereof) summarized in this section are for illustration purposes. The invention(s) disclosed and described herein are not limited to the examples summarized in this section or to any other example disclosed elsewhere herein. Any of the examples disclosed in this section, and any features of any of the examples, may be used together with each other in any combination, so long as the example (or feature(s) thereof) are not mutually exclusive. Further, any example (or feature(s) thereof) disclosed in any other section of this disclosure may be combined with any other example (or feature(s) thereof) disclosed in this section and / or any other section, in any combination, so long as the example (or feature(s) thereof) are not mutually exclusive.

[0514] Example 1: A system comprising: (i) a laser cutting subassembly; (ii) an ink printing subassembly comprising one or both of a color printhead and a black printhead; (iii) a housing comprising one or more laser blocking components configured to prevent laser light from the laser cutting subassembly from escaping the housing during operation of the laser cutting subassembly; (iv) a material feeding subassembly configured to move material through an interior portion of the housing when processing the material by the laser cutting subassembly and the ink printing subassembly; (v) one or more processors; and (vi) tangible, non-transitory computer readable media comprising program instructions. In some embodiments, the program instructions, when executed by the one or more processors, cause the system to perform functions comprising, while a region of material is positioned within the housing, (i) applyinglaser power to the region of material positioned within the housing via the laser cutting subassembly and (ii) applying ink to the region of material positioned within the housing via the ink printing subassembly.

[0515] In some embodiments of Example 1, the program instructions, when executed by the one or more processors, cause the system to perform functions additionally or alternatively comprising: (i) applying ink to the region of material positioned within the housing via one or both of the color printhead and the black printhead of the ink printing subassembly, wherein ink from the color printhead is applied to a first portion of the region and ink from the black printhead is applied to a second portion of the region, and (ii) applying laser power to the region of material positioned within the housing via the laser cutting subassembly, wherein laser power from the laser cutting subassembly is applied to a third portion of the region, wherein the third portion of the region is positioned between the first portion of the region and the second portion of the region.

[0516] Example 2: The system of Example 1, further comprising a scanner subassembly. In this example, the tangible, non-transitory computer readable media comprising program instructions that, when executed by the one or more processors, cause the system to perform functions comprising: (i) capturing image data corresponding to an item via the scanner subassembly; and (ii) processing the material with one or both of the laser cutting subassembly or the ink printing subassembly based at least in part on the image data corresponding to the item.

[0517] Example 3: The system of Example 1, wherein (A) the laser cutting subassembly comprises a laser cutting head, wherein the laser cutting head is configured to apply the laser power to the region of material positioned within the housing; and (B) the ink printing subassembly comprises at least one of (i) an ink printing head, wherein the ink printing head comprises a plurality of nozzles arranged to apply ink to the region of material positioned within the housing or (ii) a toner storage unit and a photoreceptor unit, wherein the photoreceptor unit is configured to transfer toner from the toner storage unit to a region of the material positioned within the housing.

[0518] Example 4: The system of Example 3, further comprising a gantry subassembly configured to facilitate movement of the laser cutting head along a first axis, andwherein the material feeding subassembly is configured to move material to be processed by the system along a second axis that is different than the first axis.

[0519] Example 5: The system of Example 1, wherein: (i) the laser cutting subassembly comprises a laser cutting head, wherein the laser cutting head is configured to apply the laser power to the region of material positioned within the housing; (ii) the ink printing subassembly comprises an ink printing head, wherein the ink printing head comprises a plurality of nozzles arranged to apply ink to the region of material positioned within the housing; and (iii) wherein the tangible, non-transitory computer readable media comprising program instructions. In some embodiments of Example 5, the program instructions, when executed by the one or more processors, cause the system to perform functions comprising: (A) a gantry subassembly configured to facilitate movement of the laser cutting head and the ink printing head along a first axis either (i) together with each other (ii) independently of each other; and (B) wherein the material feeding subassembly is configured to move material to be processed by the system along a second axis that is different than the first axis.

[0520] Example 6: The system of Example 5, wherein the gantry subassembly configured to move the laser cutting head and the ink printing head independently of each other is further configured to: (i) when processing a region of the material with the laser cutting head, moving the laser cutting head over the region of the material while the ink printing head is parked at a position within the housing away from the region of the material being processed by the laser cutting head; and (ii) when processing the region of the material with the ink printing head, moving the ink printing head over the region of the material while the laser cutting head is parked at a position within the housing away from the region of the material being processed by the ink printing head.

[0521] Example 7: The system of Example 5, wherein the gantry subassembly is further configured to facilitate movement of one or both of the laser cutting head and the ink printing head along the second axis.

[0522] Example 8: The system of Example 5, wherein one or both of the laser cutting head and the ink printing head are removable from the gantry subassembly.

[0523] Example 9: The system of Example 5, wherein the gantry subassembly comprises a shared processing head that includes both the laser cutting head and the ink printing head.

[0524] Example 10: The system of Example 5, wherein the gantry subassembly comprises a track extending along the first axis, and wherein the gantry subassembly is configured to facilitate movement of both the laser cutting head and the ink printing head along the track.

[0525] Example 11 : The system of Example 5, wherein the gantry subassembly comprises a first track extending along the first axis and a second track substantially parallel to the first track, and wherein the gantry subassembly is configured to facilitate (i) movement of the laser cutting head along the first track and (ii) movement of the ink printing head along the second track.

[0526] Example 12: The system of Example 1, wherein the housing further comprises: (A) a material ingress, wherein the material ingress is configured to prevent laser light from escaping the housing during operation of the laser cutting subassembly; (B) a material egress, wherein the material egress is configured to prevent laser light from escaping the housing during operation of the laser cutting subassembly; and (C) wherein the material feeding subassembly comprises one or more cylindrical rollers arranged to (i) receive material inserted into the material ingress, and (ii) while the system is processing the material, move at least a portion of the material through an interior space of the housing and out of the housing via the material egress.

[0527] Example 13: The system of Example 1, wherein the material feeding subassembly is configured to guide the material through the system such that a surface of the material processed by the laser cutting subassembly is kept within a threshold distance of a focal length of a laser emitted from the laser cutting subassembly.

[0528] Example 14: The system of Example 13, wherein the material feeding subassembly comprises one or more sprung members configured to hold the material within the threshold distance of the focal length of a laser emitted from the laser cutting subassembly while the material is processed by the laser cutting subassembly.

[0529] Example 15: The system of Example 1, wherein for a material comprising a first side and a second side, at least one of (i) the laser cutting subassembly and the ink printing subassembly are both arranged to process the first side of the material, or (ii) the laser cutting subassembly is arranged to process the first side of the material and the ink printing subassembly is arranged to process the second side of the material.

[0530] Example 16: The system of Example 1 , wherein the program instructions comprise program instructions that, when executed by the one or more processors, cause the system to perform a calibration procedure comprising: (A) printing a first calibration design on a surface of the material via the ink printing subassembly; (B) cutting a second calibration design on the surface of the material via the laser cutting subassembly; and (C) calibrating operation of the ink printing subassembly and the laser cutting subassembly based at least in part on a comparison between (i) the first calibration design printed on the surface of the material and (ii) the second calibration design cut on the surface of the material.

[0531] Example 17: The system of Example 1, wherein the program instructions comprise program instructions that, when executed by the one or more processors, cause the system to, after receiving a design file comprising ink printing instructions and laser cutting instructions, (i) process the material with the ink printing subassembly based on the ink printing instructions and (ii) process the material with the laser cutting subassembly based on the laser cutting instructions.

[0532] Example 18: The system of Example 1, further comprising a debris removal system positioned within the housing and configured to remove debris generated when processing the material with the laser cutting subassembly, wherein the debris removal system comprises one or more of: (A) a wiper assembly configured to wipe debris from a region of a surface of the material after the system has processed the region with the laser cutting subassembly; (B) a tray arranged to capture debris removed from the region of the material by the wiper assembly; and (C) an exhaust system comprising: (i) one or more filters, (ii) one or more fans configured to pull air containing debris from within the housing through the one or more filters, and (iii) one or more exhaust ports arranged to exhaust air that has been filtered by the one or more filters.

[0533] Example 19: The system of Example 1, wherein the ink printing subassembly comprises an ink printing head, wherein the ink printing head comprises a plurality of nozzles arranged to apply ink to the region of material positioned within the housing, wherein the system further comprises a moveable printhead cover, and wherein the program instructions comprise program instructions that, when executed by the one or more processors, cause the system to: (i) conceal the ink printing head via the moveable printhead cover while the system is processingmaterial with laser cutting head; and (ii) expose the ink printing head via the moveable printhead cover while the system is processing material with the ink printing head.

[0534] Example 20: The system of Example 1, further comprising a carriage, wherein the carriage comprises the laser cutting subassembly and the ink printing subassembly, and wherein the carriage comprises: (i) at least one fan; (ii) one or more air passages configured to direct airflow from the at least one fan toward a region of the material positioned within the housing where the laser cutting subassembly applies laser power to the region of material; (iii) one or more airflow sensors configured to detect whether sufficient airflow is being directed out of the one or more air passages and toward the region of the material positioned within the housing where the laser cutting subassembly applies laser power to the region of material; and (iv) at least one material movement sensor configured to monitor movement of the region of the material positioned within the housing where the ink printing subassembly applies ink to the region of material.

[0535] Example 21 : The system of Example 20, wherein the program instructions, when executed by the one or more processors, cause the system to trigger one or more safety responses when at least one of (i) the one or more airflow sensors detect that th...

Claims

CLAIMSWhat is claimed is:

1. A system comprising: a laser cutting subassembly; an ink printing subassembly comprising a color printhead and a black printhead; a housing comprising one or more laser blocking components configured to prevent laser light from the laser cutting subassembly from escaping the housing during operation of the laser cutting subassembly; a material feeding subassembly configured to move material through an interior portion of the housing when processing the material by the laser cutting subassembly and the ink printing subassembly; wherein when the ink printing subassembly applies ink to a region of material positioned within the housing via one or both of the color printhead and the black printhead, ink from the color printhead is applied to a first portion of the region and ink from the black printhead is applied to a second portion of the region; and wherein when the laser cutting subassembly applies laser power to the region of material positioned within the housing via the laser cutting subassembly, laser power from the laser cutting subassembly is applied to a third portion of the region, wherein the third portion of the region is positioned between the first portion of the region and the second portion of the region.

2. The system of claim 1, further comprising: a scanner subassembly configured to capture image data corresponding to an item via the scanner subassembly; and wherein when the system processes the material with one or both of the laser cutting subassembly or the ink printing subassembly, the system processes the material based at least in part on the image data corresponding to the item.

3. The system of claim 1, wherein: the laser cutting subassembly comprises a laser cutting head, wherein the laser cutting head is configured to apply the laser power to the region of material positioned within the housing via one of (i) an on-subassembly laser housed within the laser cutting subassembly or(ii) an off-subassembly laser separate from the laser cutting subassembly, wherein laser power from the off-subassembly laser is routed from the off-subassembly laser to the laser cutting subassembly via an optical path between the off-subassembly laser and the laser cutting subassembly; and the ink printing subassembly comprises at least one of (i) an ink printing head, wherein the ink printing head comprises a plurality of nozzles arranged to apply ink to the region of material positioned within the housing or (ii) a toner storage unit and a photoreceptor unit, wherein the photoreceptor unit is configured to transfer toner from the toner storage unit to a region of the material positioned within the housing.

4. The system of claim 3, further comprising: a gantry subassembly configured to facilitate movement of the laser cutting head along a first axis; and wherein the material feeding subassembly is configured to move material to be processed by the system along a second axis that is different than the first axis.

5. The system of claim 1, further comprising: a gantry subassembly configured to facilitate movement of the laser cutting subassembly and the ink printing subassembly along a first axis either (i) together with each other (ii) independently of each other, wherein: the laser cutting subassembly comprises a laser cutting head configured to apply the laser power to the region of material positioned within the housing via one of (i) an on-subassembly laser housed within the laser cutting subassembly or (ii) an off-subassembly laser separate from the laser cutting subassembly, wherein laser power from the off-subassembly laser is routed from the off-subassembly laser to the laser cutting subassembly via an optical path between the off- subassembly laser and the laser cutting subassembly; the ink printing subassembly comprises an ink printing head comprising a plurality of nozzles arranged to apply ink to the region of material positioned within the housing; and the material feeding subassembly is configured to move material to be processed by the system along a second axis that is different than the first axis.

6. The system of claim 5, wherein the gantry subassembly configured to move the laser cutting head and the ink printing head independently of each other is further configured to: when processing a region of the material with the laser cutting head, moving the laser cutting head over the region of the material while the ink printing head is parked at a position within the housing away from the region of the material being processed by the laser cutting head; and when processing the region of the material with the ink printing head, moving the ink printing head over the region of the material while the laser cutting head is parked at a position within the housing away from the region of the material being processed by the ink printing head.

7. The system of claim 5, wherein the gantry subassembly is further configured to facilitate movement of one or both of the laser cutting head and the ink printing head along the second axis.

8. The system of claim 5, wherein one or both of the laser cutting head and the ink printing head are removable from the gantry subassembly.

9. The system of claim 5, wherein the gantry subassembly comprises a shared processing head that includes both the laser cutting head and the ink printing head.

10. The system of claim 5, wherein the gantry subassembly comprises a track extending along the first axis, and wherein the gantry subassembly is configured to facilitate movement of both the laser cutting head and the ink printing head along the track.

11. The system of claim 5, wherein the gantry subassembly comprises a first track extending along the first axis and a second track substantially parallel to the first track, and wherein the gantry subassembly is configured to facilitate (i) movement of the laser cutting head along the first track and (ii) movement of the ink printing head along the second track.

12. The system of claim 1, wherein the housing further comprises: a material ingress, wherein the material ingress is configured to prevent laser light from escaping the housing during operation of the laser cutting subassembly;a material egress, wherein the material egress is configured to prevent laser light from escaping the housing during operation of the laser cutting subassembly; and wherein the material feeding subassembly comprises one or more cylindrical rollers arranged to (i) receive material inserted into the material ingress, and (ii) while the system is processing the material, move at least a portion of the material through an interior space of the housing and out of the housing via the material egress.

13. The system of claim 1, wherein the material feeding subassembly is configured to guide the material through the system such that a surface of the material processed by the laser cutting subassembly is kept within a threshold distance of a focal length of a laser emitted from the laser cutting subassembly.

14. The system of claim 13, wherein the material feeding subassembly comprises one or more sprung members configured to hold the material within the threshold distance of the focal length of a laser emitted from the laser cutting subassembly while the material is processed by the laser cutting subassembly.

15. The system of claim 1, wherein for a material comprising a first side and a second side, at least one of (i) the laser cutting subassembly and the ink printing subassembly are both arranged to process the first side of the material, or (ii) the laser cutting subassembly is arranged to process the first side of the material and the ink printing subassembly is arranged to process the second side of the material.

16. The system of claim 1, wherein the system is configured to perform a calibration procedure comprising: printing a first calibration design on a surface of the material via the ink printing subassembly; cutting a second calibration design on the surface of the material via the laser cutting subassembly; and calibrating operation of the ink printing subassembly and the laser cutting subassembly based at least in part on a comparison between (i) the first calibration design printed on the surface of the material and (ii) the second calibration design cut on the surface of the material.

17. The system of claim 1, wherein after receiving a design file comprising ink printing instructions and laser cutting instructions, the system is configured to (i) process the material with the ink printing subassembly based on the ink printing instructions and (ii) process the material with the laser cutting subassembly based on the laser cutting instructions.

18. The system of claim 1, further comprising a debris removal system positioned within the housing and configured to remove debris generated when processing the material with the laser cutting subassembly, wherein the debris removal system comprises one or more of: a wiper assembly configured to wipe debris from a region of a surface of the material after the system has processed the region with the laser cutting subassembly; a tray arranged to capture debris removed from the region of the material by the wiper assembly; and an exhaust system comprising: (i) one or more filters, (ii) one or more fans configured to pull air containing debris from within the housing through the one or more filters, and (iii) one or more exhaust ports arranged to exhaust air that has been filtered by the one or more filters.

19. The system of claim 1, wherein the ink printing subassembly comprises an ink printing head, wherein the ink printing head comprises a plurality of nozzles arranged to apply ink to the region of material positioned within the housing, and wherein the system is configured to: conceal the ink printing head via a moveable printhead cover while the system is processing material with laser cutting head; and expose the ink printing head via the moveable printhead cover while the system is processing material with the ink printing head.

20. The system of claim 1, further comprising a carriage, wherein the carriage comprises the laser cutting subassembly and the ink printing subassembly, and wherein the carriage comprises: at least one fan; one or more air passages configured to direct airflow from the at least one fan toward a region of the material positioned within the housing where the laser cutting subassembly applieslaser power to the region of material; one or more airflow sensors configured to detect whether sufficient airflow is being directed out of the one or more air passages and toward the region of the material positioned within the housing where the laser cutting subassembly applies laser power to the region of material; and at least one material movement sensor configured to monitor movement of the region of the material positioned within the housing where the ink printing subassembly applies ink to the region of material.

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