Digital Printing 3D Surfaces Without Embossing Dies
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Solution Overview
Problem
Existing methods for generating three-dimensional surfaces are complex, expensive, and inefficient for small batch sizes, requiring costly embossing dies and additional intermediate elements like backing paper, which limits flexibility and accuracy.
Innovation Solution
A method and device using multiple digital printing machines to directly apply a three-dimensional structure to a carrier element, eliminating the need for expensive embossing dies and intermediate elements, with adjustable layer thickness and gloss levels using UV-curable, solvent-free binders, allowing for flexible and economical production of high-accuracy surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If embossing dies are used to create three-dimensional surfaces, then manufacturing precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent replaces complex embossing dies with a digital printing system that copies the three-dimensional structure information onto the carrier element through controlled material deposition. The digital model serves as a virtual template that guides the layer-by-layer construction of the 3D surface, eliminating the need for physical embossing tools while maintaining structural accuracy.
Solution Approach 2:
The patent substitutes the mechanical embossing system with a digital printing and curing system. Instead of using mechanical pressure and physical dies to create 3D structures, the invention uses digitally controlled material deposition followed by UV curing to achieve the same three-dimensional effect, thereby reducing mechanical complexity.
2Manufacturing precision
If embossing dies are used to create three-dimensional surfaces, then manufacturing precision is improved, but production cost increases
Solution Approach 1:
The patent employs disposable carrier elements that are digitally printed and cured to create the three-dimensional surface. These carrier elements can be discarded after use, eliminating the need for expensive, reusable embossing dies. The digital printing process allows for low-cost production of each carrier element, making the overall process more economical especially for small batch sizes.
Solution Approach 2:
The patent changes the production approach from mechanical forming to digital material deposition with controlled curing. By adjusting printing parameters such as layer thickness, material composition, and UV curing conditions, the system achieves high manufacturing precision without requiring expensive tooling, thereby reducing production costs.
3Manufacturing precision
If multiple layers are applied to create three-dimensional structure, then surface realism is improved, but production time increases
Solution Approach 1:
The patent implements a continuous production process where multiple layers are deposited and cured in sequence without interruption. The UV curing step immediately solidifies each layer, allowing the next layer to be applied without waiting for air drying. This continuous action maintains high surface realism through multiple layers while minimizing production time.
Solution Approach 2:
The patent utilizes the phase transition of the photopolymerizable binder from liquid to solid through UV-induced polymerization. This rapid phase change allows each layer to be quickly固化, enabling fast production of multi-layer three-dimensional structures without prolonged drying times, thus maintaining both surface realism and production efficiency.
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 the economical production of high-accuracy, tactilely recognizable three-dimensional surfaces with the appearance of natural materials like wood, simplifying the process and reducing costs by eliminating the need for complex matrices and intermediate elements, while allowing for adjustable gloss and enhanced surface properties.
Implementation Method 1
the binder is a UV-curable, solvent-free and water-free pigmented binder and the printed layers are cured by means of a UV irradiation device
Data Source
Figure 1~2
Figure 3~10
AI summary
The invention relates to a method for producing three-dimensional surfaces (1; 30; 40) on a carrier element (5; 31; 41), in which method a plurality of layers (22 to 25; 32 to 34; 42) arranged one above another produce a structure (2), wherein the layers (22 to 25; 32 to 34; 42) are applied in succession to the carrier element (5; 31; 41) by means of at least one digital printing press (13 to 16), and wherein at least one of the layers (22 to 25; 32 to 34; 42) serves to produce an image and contains pigmented inks or dyes which are UV-curable, in particular, in a binder.