Direct-to-Transfer Printing System with ASR and Registration Markers
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Solution Overview
Problem
Current digital printing processes for garments are slow and expensive, limited by the need for screen or die creation for each design, and struggle with unique and varying designs, especially in made-to-order (MTO) production, and are not efficient for fabrics other than cotton.
Innovation Solution
A direct-to-transfer printing system using heat presses with identification and registration symbols, an Automated Storage and Retrieval (ASR) system, and digital production processes that allow for unique designs without the need for screens or dies, enabling fast and efficient printing of custom designs on various fabrics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional digital printing processes are used for MTO garments, then unique designs can be printed, but the production speed is slow and cost is high
Solution Approach 1:
The system divides the garment decoration process into separate stages: component creation on carrier sheets is decoupled from garment application. This allows components to be pre-made and stored, then quickly applied to garments as needed, enabling both design variety and production efficiency
Solution Approach 2:
Components are created and stored on carrier sheets in advance before garments are processed. The system pre-prepares design elements with registration markers, so when a garment needs decoration, the component is already ready for rapid application without time-consuming setup
2Manufacturing precision
If screen or die creation is used for each design, then printing accuracy is improved, but the process becomes time-consuming and expensive
Solution Approach 1:
The system uses digital templates and registration markers instead of physical screens or dies. Design elements are copied onto carrier sheets with precise registration features that enable accurate placement on garments without requiring time-consuming screen or die creation for each design
Solution Approach 2:
The system changes from physical manufacturing parameters (screen/die creation) to digital parameters (registration markers and coordinates). This allows precise component placement through digital positioning rather than physical tooling, eliminating setup time while maintaining accuracy
3Reliability
If conventional heat press process is used, then component fusion to garment is achieved, but the process is slow and not efficient for MTO production
Solution Approach 1:
The system enables continuous production by pre-making components on carrier sheets and storing them for rapid application. Multiple garments can be processed in sequence with components already prepared, eliminating idle time between printing and application steps, thereby maintaining fusion quality while improving overall 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
The system enables high-speed, cost-effective printing of unique designs on individual MTO garments, significantly increasing production capacity and flexibility, allowing for rapid creation of custom designs without the limitations of traditional methods.
Implementation Method 1
Heat and pressure are applied by the heat press to the component through the carrier sheet. The component is fused to the garment by the application of heat and pressure for a period of time.
Implementation Method 2
Heat and pressure are applied by the heat press to the component through the carrier sheet.
Implementation Method 3
a component comprising a design or embellishment and an adhesive
Data Source
AI summary
The present invention provides a system and process for direct-to-transfer printing, including heat presses and corresponding heat press stations through which the heat presses are indexed, and at which garments are (1) dressed upon the heat presses; (2) the garments are pre-pressed; (3) thereafter components are sequentially placed on top of and fused with their corresponding garments by applying heat and pressure; and (4) the finished garments are unloaded from the heat presses. The present invention also provides a component on a carrier sheet for use in such a direct-to-transfer printing system and process, which includes identification and registration symbols (such as barcodes, QR codes or other suitable markings) in addition to a design or embellishment. The present invention further provides an ASR system for use with a direct-to-transfer printing system.