Full Bleed Printing on Rigid Substrates via Carrier Frame
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Solution Overview
Problem
Conventional inkjet printing on rigid substrates requires cutting the substrates to achieve full bleed printing, which is time-consuming, imprecise, and can damage the printed surface due to the need for powered cutting tools.
Innovation Solution
A system and method utilizing a carrier frame with a void to hold the rigid substrate, where the substrate is taped to the frame and printed on, allowing inkjet printers to print beyond the substrate edges onto the frame, eliminating the need for cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional inkjet printing is used on rigid substrates, then printing can be completed within substrate boundaries, but cutting is required to achieve full bleed appearance which consumes time and may damage the printed surface
Solution Approach 1:
The system separates the substrate from the printing area by introducing a carrier frame that extends beyond the substrate edges. The substrate is mounted on the frame, allowing the printing surface to be segmented from the substrate boundaries, enabling print extension beyond substrate edges without requiring post-printing cutting.
Solution Approach 2:
The carrier frame is prepared in advance with mounting features (such as channels or adhesive surfaces) that allow the substrate to be secured before printing. This preliminary setup enables the printing process to extend to the full bleed area without requiring subsequent cutting operations to achieve the desired appearance.
2Manufacturing precision
If powered cutting devices are used on rigid substrates, then full bleed appearance can be achieved, but the printed surface may be blemished or scratched
Solution Approach 1:
By segmenting the substrate from the carrier frame, the printing process can extend beyond substrate edges onto the frame itself. This eliminates the need for cutting operations that would otherwise be required to achieve full bleed appearance, thereby preventing surface damage from powered cutting devices.
Solution Approach 2:
The carrier frame serves as an intermediary between the substrate and the printing process. It provides an extended printing surface that allows full bleed printing without requiring cutting of the substrate, thus preventing surface damage while achieving the desired appearance.
3Ease of manufacture
If substrate edges are spaced from print boundaries, then printing is simpler, but the printed area is smaller than the substrate surface area
Solution Approach 1:
The solution extends the printing area into a new dimension by utilizing the carrier frame that protrudes beyond the substrate edges. This dimensional extension allows the print to reach the substrate edges (full bleed) while maintaining a simple printing process, as the printer simply prints to the edges of the carrier frame assembly.
Data Source
AI summary
A system includes a carrier frame having a void, a rigid substrate sized slightly smaller than the void, the rigid substrate is connected to the carrier frame within the void, and a tape connected to edges of the rigid substrate and the carrier frame along the edges of the rigid substrate. The system is for printing with a standard printer to provide a full bleed print on the rigid substrate.