Digital Inkjet Printing on 3D Substrates via Mid-Air Droplet Merging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current ink jet printing technologies are inadequate for effectively printing on three-dimensional substrates due to issues with droplet trajectory errors and resolution, which limits their ability to create detailed and realistic bas-relief sculptures or other three-dimensional artworks.
Innovation Solution
The development of a digital inkjet printing system that accommodates larger jetting distances and uses multiple drive pulses to produce larger droplets, combined with advanced control systems to manage slope and dynamic slope errors, allowing for precise ink deposition on substrates with varying topography.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If smaller ink droplets are used to achieve higher resolution printing, then printing resolution is improved, but flight distance must be reduced which limits applicability to three-dimensional substrates
Solution Approach 1:
The patent changes the physical parameters of the ink droplets by using larger droplet sizes (greater than 20 μm diameter) compared to conventional small droplets. This parameter change allows the droplets to maintain stability and accuracy over longer flight distances, enabling printing on three-dimensional substrates while preserving acceptable resolution through controlled droplet deposition patterns
2Length of stationary object
If larger ink droplets are used to increase flight distance capability, then flight distance is improved, but printing resolution deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the ink deposition into multiple controlled droplets that are strategically placed and allowed to merge in mid-air. This creates effectively larger coverage areas while maintaining control over the final deposited pattern, resolving the contradiction between droplet size and resolution
3Manufacturing precision
If the print head is positioned closer to the substrate to maintain droplet accuracy, then manufacturing precision is improved, but adaptability to three-dimensional substrates worsens
Solution Approach 1:
The patent transitions from two-dimensional printing constraints to three-dimensional substrate accommodation by allowing the print head to operate at varying distances and angles. The system adapts to the Z-dimension of relief sculptures by adjusting droplet trajectories and using larger droplets that can bridge greater distances while maintaining placement accuracy through controlled deposition patterns
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 creation of high-resolution, detailed three-dimensional prints with improved drop integrity and reduced errors, enabling the production of realistic and accurate bas-relief sculptures and other three-dimensional artworks with enhanced realism.
Implementation Method 1
generating ink drops having a diameter greater than 20 μm
Implementation Method 2
ink jet printing technology
Implementation Method 3
depositing a pattern with ink jet technology
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
Techniques are presented for digital ink jet printing upon a substrate with a significant third dimension. Droplets in the range of 120 pL to 200 pL have been found suitable for substrates with variability, in the third dimension, of up to approximately 4 cm. A larger droplet can be generated by utilizing a plurality of drive pulses, each of which generates a smaller droplet, and having the plurality of smaller droplets combine in mid-air. The data to be printed can be derived from a 3D model and such 3D model can also be used to guide shaping of the substrate. The 3D model can be produced from 2D image data. If the 2D image data is a two-dimensional portrait photograph, a result, of using the present invention, can be a realistic portrait in the form of a bas-relief sculpture.