Direct-to-Object Printer with Dynamic Printhead for 3D Surfaces
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Solution Overview
Problem
Existing direct-to-object (DTO) printers are limited in printing high-quality images on three-dimensional objects with non-uniform surfaces, such as frustoconical shapes like buckets, due to their reliance on two-dimensional printing techniques that struggle with protrusions and varying diameters.
Innovation Solution
A system comprising a housing with a rod driven by a motor, an object rotating subsystem, a vacuum source, multiple printheads, a curing lamp, and a controller that allows for the object to be rotated and positioned precisely to accommodate its shape, enabling the printheads to print on complex surfaces by creating negative pressure and adjusting their position relative to protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If 2D flatbed printing techniques are used on DTO printers, then the printing process is simple and easy to implement, but the printer is limited to printing on flat surfaces and cannot handle three-dimensional objects with protrusions
Solution Approach 1:
The printhead assembly is made dynamically adjustable with motors that control its position and orientation. The system can move the printhead closer to or farther from the object surface and rotate it to different angles, enabling adaptation to three-dimensional surfaces with varying curvature and protrusions while maintaining printing capability
Solution Approach 2:
The invention transitions from 2D flatbed printing to 3D adaptive printing by adding degrees of freedom in motion control. The printhead can operate in multiple spatial dimensions, adjusting its position relative to the object surface in x, y, and z directions, and rotating about multiple axes to print on complex three-dimensional geometries
2Manufacturing precision
If the printhead traverses close to the surface of the print media, then printing precision is improved, but the printer cannot accommodate objects with large protrusions or non-uniform surfaces
Solution Approach 1:
The printhead assembly incorporates motorized positioning systems that allow dynamic adjustment of the distance between the printhead and object surface. This enables the system to maintain optimal printing precision by adapting the printhead-to-surface distance based on the local geometry of the object, whether flat or protruding
Solution Approach 2:
The system changes operational parameters including printhead position, orientation, and distance from the surface based on real-time detection of object geometry. By dynamically adjusting these parameters, the system maintains high printing precision across surfaces with varying curvature and protrusions
3Adaptability or versatility
If DTO printers are designed to print on three-dimensional objects, then adaptability to different object shapes is improved, but the device complexity increases significantly
Solution Approach 1:
While dynamic components increase complexity, they enable the system to handle three-dimensional objects. The motorized printhead assembly with multiple degrees of freedom allows adaptation to various object shapes, and the control system coordinates these movements to maintain printing quality across complex geometries
Solution Approach 2:
The system incorporates sensors that detect object geometry and provide feedback to the control system. This feedback mechanism allows the printer to automatically adjust printhead position, orientation, and printing parameters based on the detected object shape, reducing the need for manual configuration and simplifying operation despite the complex hardware
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 high-quality image printing on three-dimensional objects with non-uniform surfaces, maintaining image integrity and accommodating protrusions and varying diameters, thus overcoming the limitations of traditional DTO printers.
Implementation Method 1
creating negative pressure with a vacuum source operatively connected to a spindle; securing the object to a carrier
Data Source
AI summary
A system for printing images on an object, the system including, a housing, a rod driven by a first motor, an object rotating subsystem positioned about the rod and arranged for reciprocal movement, an object rotating subsystem that includes a spindle and a second motor connected to the spindle and configured to rotate the object in a first rotational direction or a second rotational direction. The system further including a vacuum source connected to the spindle, a plurality of printheads, a curing lamp, and a controller connected to the plurality of printheads, the first motor, the second motor, the curing lamp, the controller configured to operate the first motor, the second motor, the plurality of printheads, and the curing lamp, wherein the plurality of printheads are configured to eject a first marking material onto the object and the second motor rotates the object in the first or second rotational direction.