Additive Manufacturing for Personalized Substrates

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Solution Overview

Problem

Existing methods for personalizing and serializing substrates, such as identification cards and credit cards, face durability and security issues due to the peeling or wearing off of varnish or laminate layers that encapsulate ink, leading to degradation or alteration of personalization or serialization information.

Innovation Solution

Additive manufacturing is used to create layers of substrate material with embedded personalization or serialization information, forming a monoblock with high bond strength that cannot be easily altered or peeled apart, enhancing security and durability by integrating the information within the material structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If ink is deposited on the substrate surface and encapsulated with varnish or film, then the personalization information can be protected, but the encapsulation layer can be peeled back or wear off allowing the ink to be exposed and altered

Engineering Contradiction:

Improvesecurity and durability of personalization informationVSAvoidintegrity of encapsulation layer

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent merges the personalization information directly into the substrate material structure through additive manufacturing. The serialization and personalization data are embedded within the substrate layers during the manufacturing process itself, creating a unified monoblock structure where the information becomes an intrinsic part of the material rather than a surface application that requires separate encapsulation protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent transitions from two-dimensional surface printing to three-dimensional embedding within the substrate. By using additive manufacturing to deposit material layer-by-layer, the personalization information is created within the thickness dimension of the substrate, forming a volumetric structure that cannot be accessed by surface-level peeling or scratching.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Ease of manufacture

If laser etching is used to mark the substrate surface, then personalization information can be added, but the etched information can be worn off or altered over time

Engineering Contradiction:

Improvesimplicity of personalization processVSAvoiddurability of serialized information

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent combines the personalization process with the substrate manufacturing process itself. Rather than applying information to a finished substrate, the serialization data is integrated into the substrate material during additive manufacturing, creating a single unified structure where the information and the substrate are inseparable.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces mechanical surface etching with additive material deposition. Instead of removing material to create contrast (laser etching), the system adds material in precise patterns to form the personalization information, creating a positive relief structure that is more resistant to wear and alteration.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If additive manufacturing is used to create a monoblock structure with embedded information, then the information cannot be easily altered or peeled apart, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvesecurity against alterationVSAvoidcomplexity of manufacturing process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the fundamental manufacturing parameter from surface application to volumetric construction. By utilizing additive manufacturing's layer-by-layer deposition capability, the system embeds personalization information within the substrate thickness, transforming the information from a surface phenomenon to a volumetric feature that requires breaking through the material to access or alter.

Inventive Principle:

Principle #35Parameter changes

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 method provides a secure and durable solution by embedding personalization or serialization information within the substrate layers, preventing alteration or degradation, and ensuring the information remains readable over time.

Implementation Method 1

Additive manufacturing, the process of creating an object by building it one layer at a time such as through three-dimensional (3D) printing

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS11958311B2Additive manufacturing for personalization or serialization of a substrate

Publication Date: 2024.04.16 TOPPAN SECURITY SAS

AI summary

Techniques for using additive manufacturing for applying personalization or serialization information to a substrate are described herein. The techniques may include providing a base substrate formed from a first material such as polyvinyl chloride, polyester, or polycarbonate and applying, via an additive manufacturing process such as three-dimensional printing, a layer to at least a portion of the base substrate. The layer can include at least one of personalization or serialization information. The layer can be formed from the same material as the substrate or formed from a second material with substantially similar material properties as the substrate material.