Inkjet Stitching on Curved Surfaces via Angle Control
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Solution Overview
Problem
Inkjet printing on curved surfaces faces challenges with image stitching due to varying angles of inkjet drops, resulting in differences in dot pitch and color density at stitch boundaries, which are not effectively addressed by existing methods.
Innovation Solution
A method and system that determine the angle of incidence for inkjet drops on a curved surface and select a stitch point to keep the difference in angles within a predetermined range, ensuring matching dot pitches between adjacent printhead positions, allowing for effective image stitching similar to flat surface printing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If inkjet drops are jetted at varying angles on curved surfaces, then the ability to print on diverse surface geometries is improved, but the dot pitch consistency and color density uniformity deteriorate
Solution Approach 1:
The patent applies local quality by selecting specific stitch points in the overlap area where the angle of incidence for inkjet drops is controlled to be within a predetermined range. This ensures that at the critical stitching location, the dot pitch and color density are uniform, while other areas of the curved surface can accommodate varying angles. The stitch point selection criterion specifically targets locations where angle differences between adjacent printheads are minimized, creating local uniformity at the boundary while maintaining overall versatility for curved surface printing.
2Device complexity
If a single boundary line stitch is used on curved surfaces, then the printing process complexity is reduced, but the image continuity and quality at stitch boundaries deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-determining the optimal stitch point location in the overlap area before actual printing occurs. The system calculates the angle of incidence for potential stitch points and selects the location where angle differences between adjacent printheads are within acceptable ranges. This preliminary selection ensures that when the single boundary line stitch is executed, it occurs at the most favorable location for maintaining image continuity, thus achieving good stitching quality without increasing process complexity.
3Manufacturing precision
If interleaved stitching with multiple rows of drops is used, then the transition between swathes is improved, but the printing time and data processing complexity increase
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the stitch point selection based on the angle of incidence parameter. Instead of using a fixed stitching approach or always employing interleaved stitching, the system changes the critical parameter of stitch point location to optimize for angle uniformity. This allows the system to achieve smooth transitions between swathes by selecting the optimal single boundary line location, avoiding the time penalty of interleaved stitching while maintaining image quality through parameter optimization.
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
This approach ensures that the dot pitches in the stitch region match within acceptable limits, improving the quality of printed images on curved surfaces by maintaining consistent color density and enabling both flat and interleaved stitching techniques.
Implementation Method 1
Such actuators include piezoelectric actuators for example
Data Source
AI summary
A method includes providing a printhead for printing an image on a surface from two different printhead positions relative to the surface, the two different printhead positions at first and second orientations, wherein the at least one printhead and the surface move relative to each other along a print path having two potentially overlapping swathes, determining an overlap area on the surface for the two overlapping swathes wherein the overlap area is to be printed on from either of the two different printhead positions, determining for each position in the overlap area at which an inkjet drop may be printed the angle of incidence at the surface of that drop, and selecting a stitch point or region in the overlap area wherein the difference between the angles of incidence at the surface of drops from the two printhead positions is kept within an acceptable limit.