Color density based thickness compensation printing
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Solution Overview
Problem
Current printing technologies face challenges in achieving precise control over color thickness and structural layers on three-dimensional objects, particularly on curved or complex surfaces like articles of apparel and footwear, leading to uneven surface profiles and inadequate aesthetic or functional outcomes.
Innovation Solution
A method and system that determine target thickness for regions of a three-dimensional object, assigning color and structural layers based on color density and target thickness, allowing for independent control of color and structural thicknesses to achieve a desired surface profile, using a print controller and printing device that transmit and execute precise print instructions for each pixel or region.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If current printing technologies are used on three-dimensional objects, then printing can be performed on complex surfaces, but the surface profile becomes uneven and thickness control is imprecise
Solution Approach 1:
The printing process is segmented into two independent stages: color printing and structural layer printing. This segmentation allows each stage to be optimized independently - color printing for aesthetic quality and structural layer printing for precise thickness control and surface profile management.
Solution Approach 2:
The patent applies different printing strategies to different regions of the three-dimensional object. Color layers are printed with aesthetic considerations, while structural layers are printed with functional thickness requirements. Each region can have customized color and structural properties to meet local requirements.
2Illumination intensity
If color layers are printed to achieve desired color intensity, then aesthetic quality improves, but structural thickness becomes uncontrolled
Solution Approach 1:
The patent divides the printing function into two separate systems: a color printing system that optimizes for color intensity and aesthetic quality, and a structural layer printing system that optimizes for precise thickness control. This segmentation resolves the conflict between achieving desired color intensity and maintaining controlled structural thickness.
Solution Approach 2:
The patent merges color layers and structural layers into a single integrated printing process that operates in two sequential stages. The color layers provide aesthetic properties while the structural layers provide controlled thickness, and both are combined to form the final three-dimensional printed object with both aesthetic and functional qualities.
3Manufacturing precision
If structural layers are added to control thickness, then surface profile control improves, but device complexity increases
Solution Approach 1:
The printing system is segmented into two functional modules: a color printing module and a structural layer printing module. Each module has specialized capabilities - the color module handles aesthetic printing while the structural module handles precision thickness control. This segmentation manages device complexity by creating specialized, optimized subsystems rather than requiring a single complex system to handle all functions.
Data Source
AI summary
This application discloses methods of printing a three-dimensional object on a base using a printing device. One method includes printing a color layer of the three-dimensional object onto a region of the base. The color layer has a color thickness corresponding to a selected color intensity of a color. The method also includes determining a structural thickness for a structural layer of the three-dimensional object by calculating a difference between the color thickness and a target thickness of the three-dimensional object. The target thickness is greater than the color thickness. The method further includes printing the structural layer having the structural thickness directly onto the color layer.