3D Printing on Fabric Using Bi-Adhesive Film for Smooth Surface Finish
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Solution Overview
Problem
3D printing on substrates with irregular surfaces, such as fabric, results in visible surface irregularities and a less homogeneous structure, affecting the aesthetic appearance and durability of the printed objects due to the layers following the substrate's reliefs and cavities.
Innovation Solution
A process involving a 3D printer with a bi-adhesive polymeric glue film as a printing support, allowing the printing of 3D works with a smooth surface, followed by trimming excess glue and heat-sealing the work onto the substrate using a hot press to ensure a secure and defect-free bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If 3D printing is performed directly on fabric substrate, then the printing process can be completed, but the visible surface shows roughness and cavities following the fabric weave irregularities
Solution Approach 1:
A release film is introduced as an intermediary layer between the 3D printer and the fabric substrate. This release film provides a smooth printing surface that prevents the printer's layers from following the fabric's irregularities, while still allowing the printed work to be transferred to the fabric through heat pressing. The release film acts as a mediator that decouples the printing process from the substrate irregularities.
2Adaptability or versatility
If 3D printing layers follow the fabric reliefs and cavities, then the printing process adapts to the substrate, but the printed object's structure becomes less homogeneous and more prone to breakage
Solution Approach 1:
The release film serves as a mediator that allows the printed object to maintain structural homogeneity by providing a flat printing surface, while still enabling adaptation to the fabric substrate through the heat pressing transfer process. The printed layers remain uniform and horizontal on the release film, preventing weakness points, while the final transfer achieves substrate adaptation.
3Productivity
If 3D printing is performed on irregular substrate surfaces, then the process can be completed, but the visible surface shows visible defects affecting aesthetic appearance
Solution Approach 1:
The release film provides a smooth intermediate surface during printing that ensures high aesthetic quality of the visible surface. After printing, the release film is removed and the printed work is transferred to the fabric substrate through heat pressing, maintaining the smooth visible surface while completing the printing process on the irregular substrate.
4Manufacturing precision
If a release film is introduced between the printer and substrate, then surface smoothness is improved, but the device complexity increases
Solution Approach 1:
A simple release film serves as the intermediary element, adding minimal complexity to the printing system. The release film is a straightforward component that can be easily handled, removed, and replaced, providing significant surface smoothness improvement without substantially increasing device complexity.
5Strength
If the printed work is heat-pressed to the substrate, then durability and attachment strength are improved, but the processing time increases
Solution Approach 1:
The 3D printing process is performed preliminarily on the release film before transfer to the substrate. This preliminary action allows the printed object to achieve its final shape and surface quality on a smooth surface, then it is transferred to the substrate through heat pressing. The preliminary printing on the release film separates the printing and attachment processes, optimizing both quality and efficiency.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves 3D works with a smooth, regular visible surface and enhanced durability by decoupling the printing process from the substrate's irregularities, resulting in improved aesthetic quality and structural integrity.
Implementation Method 1
heat-sealing the 3D-work to the substrate
Implementation Method 2
bi-adhesive polymeric glue film
Data Source
Figure 1~4
AI summary
Process for the realization of 3D-works (12), such as writings, decorations, functional elements or other similar objects by 3D printing, applied to a substrate (11), in particular a fabric, comprising the steps of: - providing a 3D printer with a printing support (14) consisting of a film of bi-adhesive polymeric glue; - carrying out a 3D printing, applying a plurality of successive layers of 3D printing material on an adhesive surface of said bi-adhesive polymeric glue film (14) until obtaining a 3D-work (12) with a visible surface (12a) and an adhesive face (12b), consisting of the opposite adhesive surface of the bi-adhesive polymeric glue film (14); - removing the 3D-work (12) from the 3D printer; - trimming any excess (15) of the bi-adhesive polymeric glue film (14) with respect to the outline of the 3D-work (12); - inserting the 3D-work (12) into a hot press, with the substrate (11) adhering to its adhesive face (12b); - heat-sealing the 3D-work (12) to the substrate (11).