3D Surface Pattern Printing with Multi-Axis Print Head Control
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Solution Overview
Problem
Existing methods for printing patterns on three-dimensional surfaces, particularly those mimicking hardwood materials, are inaccurate and unsuitable for complex 3D-surfaces and simultaneous printing of multiple articles, especially when using cheaper and lighter materials like MDF or plywood.
Innovation Solution
A system comprising a printer head with drive arrangements and a control system that allows precise movement along multiple axes to adapt to the three-dimensional surface, using UV or waterborne ink with curing units to ensure accurate pattern application on materials like MDF, HDF, or wood substrates with veneers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional staining method is used to apply wood pattern to cheaper material, then cost is reduced, but manufacturing precision deteriorates due to unpredictable absorption and inaccuracy on 3D surfaces
Solution Approach 1:
The patent replaces the traditional mechanical staining process (dipping, wiping, spraying) with a digital printing system that uses UV-curable ink and photopolymerization. This substitution eliminates the unpredictable absorption issues of traditional staining and enables precise pattern application on 3D surfaces through computer-controlled print head movement and curing.
Solution Approach 2:
The patent changes the chemical state of the ink from water-based (traditional staining) to UV-curable ink that transitions from liquid to solid upon UV exposure. This parameter change allows the ink to remain on the surface without absorption issues and enables precise curing only where needed, improving pattern accuracy on complex 3D surfaces.
2Device complexity
If traditional staining method is used, then simpler equipment is required, but reliability deteriorates due to unsuitability for 3D surfaces and multiple articles
Solution Approach 1:
The patent moves from 2D flat surface printing to 3D surface printing by enabling the print head to follow complex surface topography. The system uses multiple degrees of freedom in motion control and UV curing to adapt to three-dimensional surfaces, making the process reliable for curved, angled, and irregular geometries that traditional staining cannot handle.
Solution Approach 2:
The patent creates a universal printing system that can handle multiple work pieces simultaneously and adapt to various 3D surface geometries. The modular work piece unit and programmable control system allow the same equipment to process different articles with different shapes, sizes, and surface complexities, enhancing reliability across diverse applications.
3Manufacturing precision
If digital printing method is used to print pattern onto material, then manufacturing precision is improved, but device complexity increases and simultaneous printing of multiple articles becomes difficult
Solution Approach 1:
The patent segments the printing system into modular components: a printer head assembly, a work piece unit, and a control system. This segmentation allows the system to handle multiple work pieces by positioning them on the work piece unit, with the printer head servicing multiple articles through coordinated motion. The modular design manages complexity while enabling multi-article processing.
Solution Approach 2:
The patent employs dynamic motion control where the printer head can move in multiple axes and the work piece unit can be positioned and oriented dynamically. This dynamic capability allows precise pattern application on 3D surfaces while efficiently processing multiple articles through automated repositioning, managing system complexity through programmable motion sequences.
4Weight of moving object
If cheaper materials like MDF or plywood are used instead of hardwood, then weight is reduced and cost is lowered, but aesthetic quality deteriorates without proper pattern application
Solution Approach 1:
The patent uses UV-curable ink with various pigments to change the color and appearance of the work piece surface. The ink can replicate wood grain patterns, knots, and other aesthetic features of expensive hardwoods on cheaper materials like MDF or plywood. The UV curing process ensures the color remains vibrant and durable, transforming the aesthetic quality of the material.
Solution Approach 2:
The patent uses digital printing to copy the appearance of expensive hardwood surfaces onto cheaper substrates. The system can store and reproduce wood grain patterns, textures, and color variations digitally, creating accurate visual copies of premium materials on lightweight, cost-effective bases like MDF, plywood, or rubberwood.
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
Enables accurate and efficient printing of patterns on complex 3D-surfaces, providing cost-effective and lightweight materials with hardwood aesthetics, suitable for furniture components.
Implementation Method 1
The UV-ink is configured to apply UV-ink to the three-dimensional surface to print the pattern. The curing unit is configured to illuminate the three-dimensional surface of the work piece with UV-light for drying the UV-ink applied by the printer head onto said three-dimensional surface.
Data Source
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Figure 4~5
AI summary
The present invention relates to a system (100) and method (1000) for printing a pattern on a three-dimensional surface (11) of a work piece (10). The system comprises a printer head (400) configured to apply the pattern on the three-dimensional surface (11) of the work piece (10) and a printer head drive arrangement (300) configured to drive the printer head (400) along a first printer head direction (PHI), a second printer head direction (PH2) orthogonal to the first printer head direction (PHI) and about a tilting axis (TA) extending orthogonal to the second printer head direction (PH2).