3D Printing Wood Grain Surface via Digital Depth Conversion
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Solution Overview
Problem
Current methods for producing articles with material effects, such as wood grain finishes, are complex, time-consuming, and costly, often resulting in inconsistent and low-quality decorative outcomes.
Innovation Solution
A three-dimensional printing process that converts digital images of wood grain patterns into spatial depth models, using a molding device to create articles with variable groove depths, followed by painting to recreate the visual and tactile effects of wood, simplifying operations and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional decoration processes (sublimation, powder deposition, decorative film application) are used to obtain material effect, then material effect decoration can be achieved, but the processes become very complex, requiring long times and complex operating conditions with increased production costs
Solution Approach 1:
The patent combines multiple separate operations (surface preparation, decoration application, and finishing) into a single integrated 3D printing process. The digital model directly guides the deposition of decorative materials layer by layer, eliminating the need for separate sublimation, powder deposition, or film application steps, thereby simplifying the overall process while maintaining high decoration precision
Solution Approach 2:
The patent replaces complex mechanical decoration systems (sublimation chambers, powder deposition equipment, film application machinery) with a digital 3D printing system. The digital model and controlled material deposition replace the need for complex mechanical operating conditions, reducing both device complexity and operational complexity
2Manufacturing precision
If traditional decoration processes are used to obtain material effect, then decoration can be applied, but production times are prolonged
Solution Approach 1:
The patent performs preliminary digital modeling and simulation before actual production. The digital model预先 defines the exact decoration pattern, material placement, and layer thickness, allowing the 3D printing process to execute directly without intermediate preparation steps, thereby accelerating production while ensuring high decoration quality
Solution Approach 2:
The 3D printing process enables continuous material deposition and layer building without the interruptions required by traditional methods (heating cycles for sublimation, multiple coating passes for powder deposition, film application and lamination steps). This continuous action significantly reduces production time while maintaining consistent decoration quality throughout
3Manufacturing precision
If traditional decoration processes are used, then material effect can be reproduced, but operating conditions become complex and costly
Solution Approach 1:
The patent transforms the decoration process from physical/chemical parameter control (temperature for sublimation, powder particle size and distribution, film adhesion parameters) to digital parameter control (digital model resolution, layer thickness, material deposition rate). This parameter transformation simplifies manufacturing by replacing complex physical operating conditions with easily adjustable digital settings while maintaining precise material effect reproduction
Solution Approach 2:
The patent uses digital copying of the desired material effect into a 3D model, which then guides the physical reproduction process. Instead of manually preparing surfaces and applying decorations, the digital copy contains all necessary information for automated material placement, greatly simplifying manufacturing while ensuring accurate material effect reproduction
4Manufacturing precision
If traditional decoration methods are applied, then surface decoration can be achieved, but production costs increase
Solution Approach 1:
The 3D printing system applies decorative materials with local precision, depositing material only where specified in the digital model. This eliminates waste associated with traditional methods where entire surfaces must be treated uniformly (sublimation requires heating the entire surface, powder deposition coats the whole area, film application covers the complete surface). Local quality application reduces material consumption and production costs while maintaining high decoration accuracy
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
This process achieves a precise and realistic material effect, reducing production time and costs while ensuring high aesthetic value and mechanical strength, with the ability to produce articles efficiently and effectively.
Implementation Method 1
at least one three-dimensional printing step of the model in order to obtain the manufactured article with material effect 3 by means of at least one molding device 10, 13
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The three-dimensional printing process for obtaining a manufactured article with material effect comprises: a supply step of an image (1) in digital format reproducing a wooden surface portion provided with a plurality of grains (2), comprising a plurality of pixels; an identification step of a color range datum of each of pixels by means of a software; a transformation step of the color range datum into a depth spatial datum to produce a three-dimensional digital model of a manufactured article with material effect (3) provided with an outer surface (4) reproducing the grains (2) by means of a plurality of grooves (5) with variable depth; a three-dimensional printing step of the model to obtain the manufactured article with material effect (3) by means of a molding device (10, 13); and a painting step of the outer surface (4) by means of a paint (9), the paint (9) accumulating in the grooves (5) and reproducing the color range of the grains (2).