Direct Printing Correction for Complex Container Topologies
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Solution Overview
Problem
Direct printing on containers with complex surface topologies faces challenges in maintaining printing quality due to distortions caused by non-circular shapes, which existing correction methods struggle to adequately address, especially requiring high computing power and manual interventions.
Innovation Solution
A method that utilizes a 3D printing model to predict the printing movement path and parameters, allowing for both macroscopic and microscopic corrections to be applied, reducing computing complexity and manual steps by correcting distortions before rasterization and adjusting ink drop flight times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing distortion correction methods are used for printing on containers with complex surface topology, then printing quality can be improved, but the computing power required becomes excessively high
Solution Approach 1:
The correction process is divided into two independent stages: macroscopic correction (distortion compensation) and microscopic correction (nozzle-specific adjustments). This segmentation allows each stage to be optimized separately, reducing overall computational complexity while maintaining printing quality.
Solution Approach 2:
The macroscopic correction is performed in advance on the graphic template before rasterization. By pre-correcting the template based on the 3D container model and printing geometry, the system avoids the need for computationally intensive corrections during or after rasterization, significantly reducing real-time computing requirements.
2Manufacturing precision
If high-resolution distortion correction is applied to complex surface topologies, then printing quality improves, but the complexity of the correction process increases
Solution Approach 1:
The correction system is segmented into macroscopic and microscopic components. The macroscopic correction handles large-scale geometric distortions using the 3D container model, while the microscopic correction addresses fine-grained nozzle variations. This division simplifies the overall process by treating different scales of correction separately.
Solution Approach 2:
A 3D printing model of the container serves as an intermediary between the graphic template and the actual printing process. This model captures the container's surface geometry and enables automated calculation of correction parameters, eliminating the need for manual intervention and reducing process complexity.
3Manufacturing precision
If manual interventions are used for printing corrections on complex geometries, then printing quality can be maintained, but the number of manual steps increases
Solution Approach 1:
The system performs self-correction by automatically generating correction parameters from the 3D container model and printing geometry. The macroscopic correction algorithm automatically adjusts the graphic template based on predicted distortions, eliminating the need for manual operator intervention and enabling fully automated high-quality printing on complex geometries.
Solution Approach 2:
The 3D printing model acts as an automated intermediary that translates container geometry into correction instructions. This intermediary enables the system to automatically compensate for complex surface topologies without requiring manual measurement or adjustment, significantly reducing manual steps while maintaining printing quality.
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 improves printing quality on containers with complex geometries without excessive computing power or manual intervention, ensuring high-resolution corrections and efficient processing.
Implementation Method 1
The at least one direct print head, for example using the inkjet printing process, releases individual ink drops from active printing nozzles onto the printing area
Implementation Method 2
microscopic corrections are known in which variations in the flight time of the ink drops ejected from a direct print head are compensated for
Data Source
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AI summary
The invention relates to a direct printing method for a direct printing machine (10) for printing containers (2), in particular moulded containers, with a direct print, wherein a printing movement path of the direct printing machine (10) is created from 3D data of the containers (2), and a 3D printing model is created from printing parameters of the direct printing machine (10) in order to predict an image of a printing graphic original to be printed on the containers (2) as a direct print, wherein a macroscopic correction and a microscopic correction are determined by means of the 3D printing model, wherein the macroscopic correction comprises an inverse of a distortion of the printing graphic original on the containers (2) and the microscopic correction comprises a nozzle correction, wherein the printing graphic original is corrected with the macroscopic correction and stored in a corrected printing graphic, wherein a printing raster image is generated from the corrected printing graphic by using a raster image processor, and wherein the printing raster image (206) is corrected on the basis of the microscopic correction and stored as a corrected printing raster image and is printed onto the containers (2) by the direct printing machine (10) as the direct print.