3D Toy Figure Inkjet Printing With Shape Compensation
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Solution Overview
Problem
Existing inkjet printing methods for three-dimensional bodies, such as toy figure heads, face challenges with misaligned face decorations due to unpredictable deformations caused by production processes like injection molding, leading to a high percentage of defective faces.
Innovation Solution
An inkjet printing system that uses a fixture apparatus with a guide plate and base plate to accurately align and fix the three-dimensional body, adjusting the fixture and ink application based on an updated body template derived from topographical scanning to accommodate deformations, ensuring precise placement and orientation of decorations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional inkjet printing methods are used without accounting for production deformations, then the printing process is simple and fast, but the alignment precision of face decorations deteriorates due to unpredictable deformations from injection molding
Solution Approach 1:
The system performs preliminary topographical scanning of the three-dimensional body to capture its actual shape after production deformations. This scanning data is used to create a customized printing design that pre-compensates for the deformations, ensuring accurate alignment when the ink is applied. The fixture apparatus is also preliminarily configured based on the scanned topography to properly position the body during printing.
Solution Approach 2:
The system uses topographical scanning to obtain feedback information about the actual shape and deformations of the three-dimensional body. This feedback is fed into the printing design generation process, which adjusts the printing pattern to compensate for the measured deformations. The fixture apparatus positioning is also adjusted based on this feedback to ensure proper alignment.
2Manufacturing precision
If a fixed fixture apparatus is used for all three-dimensional bodies, then the device complexity is reduced, but the manufacturing precision deteriorates because it cannot accommodate variations in body shape and deformations
Solution Approach 1:
The fixture apparatus is designed with adjustable and reconfigurable components that can be dynamically adapted to match the specific topography of each three-dimensional body. The guide plate and positioning elements can be adjusted based on the scanned body shape, allowing the same fixture to accurately accommodate variations in body geometry and deformation patterns across different production batches.
Solution Approach 2:
The system changes the positioning parameters and geometric configuration of the fixture apparatus based on the topographical data of each body. By adjusting the fixture's parameters (such as guide plate position, clamp locations, and support points) to match the actual body measurements, the system achieves high precision without requiring a completely different fixture for each body variation.
3Reliability
If the printing design is created without topographical scanning, then the process time is reduced, but the reliability of decoration alignment deteriorates due to unpredictable deformations
Solution Approach 1:
The system creates a digital topographical copy of the three-dimensional body through scanning. This digital replica is then used to generate the printing design, allowing the system to work with an accurate virtual model of the actual body. This digital copying process captures all deformation details and enables precise alignment compensation without requiring physical trial-and-error adjustments.
Data Source
AI summary
An inkjet printing system includes: a production apparatus configured to receive an original body template and to produce a three-dimensional body based on the original body template; a metrology apparatus configured to receive the produced three-dimensional body from the production apparatus and to topographically scan the received three-dimensional body to thereby produce an updated body template of the three-dimensional body; a control apparatus in communication with the metrology apparatus; and an inkjet printing apparatus. The control apparatus is configured to receive the updated body template and to create a topographical printing design based on the updated body template. The inkjet printing apparatus is in communication with the control apparatus, and is configured to receive the three-dimensional body and apply the created topographical printing design to the three-dimensional body.