Structured Pressing Tool Surfaces from Grayscale-Guided 3D Printing
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Solution Overview
Problem
Existing methods for producing pressing tools with structured surfaces are inefficient, require environmentally harmful chemicals, and lack consistent reproducibility and wear resistance.
Innovation Solution
A method using a 3D printer to create a pressing tool with a structured pressing surface by printing plastic or lacquer layers with embedded mineral particles, controlled by 2D image data sets, ensuring precise formation of elevations and rounded edges, and optionally varying gloss levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods are used to produce pressing tools with structured surfaces, then production can proceed with standard processes, but the methods are inefficient, require environmentally harmful chemicals, and lack consistent reproducibility and wear resistance
Solution Approach 1:
The patent replaces conventional mechanical manufacturing methods (milling, turning, grinding) with a 3D printing system that uses digital models and additive manufacturing to create pressing tools. This substitution eliminates the need for harmful chemicals used in traditional processes while improving production efficiency and consistency through digital control and automation.
Solution Approach 2:
The invention changes the fundamental production parameters from subtractive mechanical processing to additive 3D printing with controlled material deposition. By adjusting printing parameters such as layer thickness, deposition rate, and material composition, the system achieves consistent reproducibility and high wear resistance without environmentally harmful chemicals.
2Reliability
If conventional manufacturing methods are used, then standard production processes can be maintained, but consistent reproducibility and wear resistance are lacking
Solution Approach 1:
The patent applies preliminary action by creating a detailed digital 3D model before manufacturing. The digital model contains all necessary geometric and material information, allowing the 3D printing system to reproduce pressing tools with consistent precision and wear resistance. This preliminary digital preparation eliminates variability in the manufacturing process.
Solution Approach 2:
The invention uses composite materials in the 3D printing process, combining base materials with reinforcement elements to achieve high wear resistance. The additive manufacturing process allows for controlled incorporation of wear-resistant materials and complex internal structures that enhance reliability while maintaining ease of manufacture through digital control.
3Manufacturing precision
If 3D printing is used to create pressing tools, then efficient and environmentally friendly production is achieved, but precise formation of elevations and rounded edges requires advanced control
Solution Approach 1:
The patent applies segmentation by dividing the pressing tool surface into discrete layers and further into individual pixels or small elements. This segmentation allows the 3D printing system to precisely control the formation of elevations and rounded edges by independently adjusting material deposition at each segment, achieving high manufacturing precision through manageable discrete units.
Solution Approach 2:
The invention transitions from 2D surface design to 3D volumetric printing by adding the vertical dimension through layer-by-layer construction. This dimensional change enables precise formation of elevations and rounded edges by controlling material deposition in three dimensions, with the printing device complexity managed through software algorithms that translate 3D models into precise manufacturing instructions.
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 efficient, environmentally friendly production of pressing tools with high wear resistance and consistent reproducibility, allowing for precise replication of structured surfaces on workpieces.
Implementation Method 1
a 3D printer is used and a process is applied, with provision and use of digitized data of a 3D topography of a surface structure, creation of digitized data of individual 2D layers of the 3D topography
Implementation Method 2
printing plastic or paint drops onto a flat base carrier with the addition of mineral particles, depending on the 2D image data sets, in order to obtain partial plastic or lacquer layers with embedded mineral particles
Implementation Method 3
the sizes of the individual plastic or paint drops depend on the grayscale values of the image data of the 2D image data sets
Data Source
Figure 1
Figure 2a~4c
Figure 5
AI summary
The invention relates to a method and a printer device (41) for producing a pressing tool (1), which is intended for producing a workpiece and has a structured pressing surface (2), which has been applied to a planar base support (21) and the structure of which has elevations (4). A 2D image file is provided, comprising image data with greyscale values which are assigned to a 2D image (71) of a structured surface assigned to the structured pressing surface (2). The greyscale values comprise information concerning heights and roundings of elevations (4) of the structure of the structured surface, and consequently information concerning heights and roundings of elevations (4) of the structure of the structured pressing surface (2). The image data from the 2D image file are used to generate 2D image data sets (53) which are assigned to layers of the structured pressing surface (2) arranged one on top of the other and are intended for activating a printer device (41). The printer device (41) is activated in such a way that, on the basis of the 2D image data sets (53) and by adding mineral particles (23), it prints drops of plastic or lacquer onto a planar base support (21), in order to obtain partial layers of plastic or lacquer (22), with mineral particles (23) embedded therein, that lie one on top of the other in layers on the planar base support (21) and form the structured pressing surface (2) of the pressing tool.