Gradient Printing of 3D Structural Components on Fabric
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Solution Overview
Problem
Existing printing technologies struggle to create three-dimensional structural components with varying thicknesses and smooth slopes on fabric-based articles, such as apparel and footwear, without requiring a flat base or release layer.
Innovation Solution
A method involving a printing device that receives predetermined thicknesses to print layers with varying thicknesses, allowing for the creation of three-dimensional structural components with smoothly sloped geometries directly on fabric surfaces, using UV-curable inks and printhead movements along multiple axes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing printing technologies are used to create three-dimensional structural components on fabric, then the printing process can be simplified, but the ability to create varying thicknesses and smooth slopes is limited
Solution Approach 1:
The printhead assembly is made dynamically adjustable along the Z-axis (vertical axis) to vary the separation distance from the fabric surface during printing. This dynamic positioning enables the deposition of ink layers with varying thicknesses, creating three-dimensional structural components with smooth slopes and gradients without requiring complex multi-layer stacking processes.
Solution Approach 2:
The invention transitions from traditional two-dimensional planar printing to three-dimensional structural printing by introducing Z-axis movement. The printhead can deposit ink at different heights and angles, creating layers with varying thicknesses that form three-dimensional structures directly on the fabric surface, eliminating the need for flat bases or release layers.
2Ease of manufacture
If traditional printing methods are used on fabric, then the process is simple, but the fabric base must be flat and require release layers
Solution Approach 1:
The printing system dynamically adjusts the printhead separation distance from the fabric surface during the printing process. This dynamic adjustment allows the system to adapt to varying fabric topographies and create three-dimensional structures directly on the fabric without requiring it to be flat or use release layers, simplifying the overall manufacturing process.
Solution Approach 2:
The invention changes the printing parameters by varying the separation distance between the printhead and fabric surface during printing. This parameter variation enables the deposition of ink layers with different thicknesses, allowing the system to create three-dimensional structural components on fabric bases of various shapes and textures without additional preparation steps.
3Shape
If multiple layers are printed to create three-dimensional structures, then the structural complexity increases, but the manufacturing time and process complexity increase
Solution Approach 1:
The printhead assembly moves dynamically along the Z-axis during a single printing pass, enabling the creation of three-dimensional structures with varying layer thicknesses in one continuous operation. This eliminates the need for multiple sequential printing passes, maintaining high printing speed while achieving complex three-dimensional shapes and smooth gradients.
Solution Approach 2:
The printing process maintains continuous useful action by depositing multiple layers of varying thickness in a single uninterrupted printing pass. The printhead continuously moves along the fabric surface while dynamically adjusting its vertical position, creating three-dimensional structures without stopping or requiring intermediate processing steps, thereby maximizing productivity.
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 production of customizable, three-dimensional structural components with varying thicknesses and smooth surfaces on fabric articles, enhancing durability and design flexibility without the need for a flat base or release layer.
Implementation Method 1
UV-curable inks
Data Source
AI summary
Methods are described herein for printing a three-dimensional structural component onto a base. For example, a method can include receiving a set of predetermined thicknesses for the three-dimensional structural component, instructing a printing device to print a set of layers of the three-dimensional structural component onto the base, and printing the three-dimensional structural component onto the base using the set of predetermined thicknesses to form a printed set of layers. The printed set of layers can include an exposed surface comprising a tall region, an intermediate region, and a short region. A difference in height between the tall region of the exposed surface and the short region of the exposed surface can be greater than a separation distance between the base and a printhead assembly of the printing device. The intermediate region of the exposed surface can have a smoothly sloped geometry.