3D Surface Printing via Composite Image Projection
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Solution Overview
Problem
Current methods fail to continuously print adjacent images on a three-dimensional surface using inkjet nozzles mounted on an X-Y table, resulting in uncoated or overlapping areas, necessitating manual drawing or pasting of printed films.
Innovation Solution
A three-dimensional printing method that captures subdivided images of the surface at fixed intervals, creates a composite print surface, edits the image to be printed to match the end edge of the previous image, and uses an inkjet printer to discharge ink based on the edited image, ensuring continuous printing without gaps or overlaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If inkjet nozzles are used to print on a three-dimensional surface, then printing automation is improved, but uncoated portions or overlapping portions are generated between adjacent images
Solution Approach 1:
The system captures an image of the three-dimensional surface before printing to create a reference map. This preliminary action allows the printing positions and ink discharge amounts to be calculated in advance, ensuring that adjacent images will connect properly without gaps or overlaps when printed on the curved surface.
Solution Approach 2:
The system uses captured images of the three-dimensional surface as feedback to adjust printing parameters. By analyzing the actual surface geometry from the captured image, the system calculates appropriate ink discharge amounts and positioning for each nozzle, ensuring continuous printing across adjacent images despite surface curvature variations.
2Productivity
If multiple images are adjacently printed on a three-dimensional surface, then productivity is improved, but gaps or overlaps occur between images
Solution Approach 1:
Before printing multiple images, the system captures a comprehensive image of the entire three-dimensional surface and calculates all printing parameters in advance. This includes determining the exact position and ink discharge amount for each nozzle across all images, ensuring that boundary alignments will be precise when images are printed adjacently on the curved surface.
Solution Approach 2:
The system uses the captured surface image as feedback to dynamically adjust printing parameters for each adjacent image. By analyzing the three-dimensional geometry from the captured data, the system ensures that boundary portions of adjacent images align continuously without gaps or overlaps, maintaining precision while enabling multi-image printing.
3Speed
If ink is discharged perpendicular to the nozzle head, then printing speed is improved, but distorted shapes are printed on curved surfaces
Solution Approach 1:
The system adjusts ink discharge parameters locally based on the three-dimensional surface geometry at each printing position. By analyzing the captured surface image, the system calculates the appropriate ink discharge amount and nozzle positioning for each local area, ensuring that shapes are printed accurately on curved surfaces while maintaining efficient printing speed through automated control.
Solution Approach 2:
The system dynamically changes printing parameters including ink discharge amount and nozzle positioning based on the three-dimensional surface geometry. By modifying these parameters according to the local surface curvature captured in the reference image, the system maintains shape accuracy on curved surfaces while preserving printing speed through automated parameter adjustment.
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 continuous printing of multiple images on a three-dimensional surface without gaps or overlaps, allowing for efficient and uniform coating of complex shapes like vehicle bodies and aircraft surfaces.
Implementation Method 1
an ink emitted through each of the inkjet nozzles mounted on a nozzle head 100 is discharged in a direction perpendicular to the nozzle head 100
Data Source
AI summary
A predetermined area of a print surface is captured by a camera as a plurality of subdivided images to include an end edge portion of a previously printed image on a coating-target object, the end edge portion serving as a connection portion with an image to be drawn to be printed contiguous to the printed image, a composite print surface, which is a plane projection of the print-target surface which is non-plane, is created on the basis of the captured subdivided images, an edited image to be drawn is created by superimposing the image to be drawn on the composite print surface, and the image to be drawn is adjacently printed contiguous to the printed image on the basis of the edited image to be drawn.