Intaglio Printing Plate Master Segmentation for Rapid Update
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Solution Overview
Problem
The production of printing plates for intaglio printing is time-consuming and expensive, particularly when changes are needed in individual areas of the printed image, such as dates or signatures, which are common in banknotes.
Innovation Solution
A method utilizing 3D printing to produce either parts of a master or a matrix, allowing for the addition of only the changing information, such as signatures or dates, while the rest of the image is created through conventional processes like milling or galvanic molding, reducing mechanical requirements and production time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional milling processes are used to produce the entire master, then high precision is achieved, but production time and cost increase significantly when changes are needed
Solution Approach 1:
The master is divided into two parts: a permanent base master containing the unchanged printed image (produced by milling with high precision) and a separate additional information carrier containing changeable elements (produced by 3D printing). This segmentation allows the unchanged high-precision portions to be created once, while only the changeable portions need to be updated, significantly reducing production time for modifications.
Solution Approach 2:
The base master is prepared in advance with all the permanent printed image elements that will not change. This preliminary creation of the stable foundation allows future modifications to only involve adding or changing the additional information carrier, rather than recreating the entire master from scratch.
2Ease of manufacture
If the entire master is milled to include additional print information, then complete image is produced, but production cost and time increase when only small changes are needed
Solution Approach 1:
The printed image is segmented into permanent elements (in the base master) and changeable elements (in the additional information carrier). This allows the complete image to be produced by combining both parts, while updates only require modifying the smaller additional information carrier rather than the entire master.
Solution Approach 2:
Different manufacturing methods are applied to different parts of the master: conventional milling is used for the high-precision permanent elements, while 3D printing is used for the changeable additional information. This local differentiation optimizes both the completeness of the image and the efficiency of updates.
3Productivity
If 3D printing is used for the entire master, then production time is reduced, but mechanical requirements and precision are compromised
Solution Approach 1:
The master is segmented into portions requiring high precision (base master, produced by milling) and portions where production speed is more critical (additional information carrier, produced by 3D printing). This segmentation allows each part to be manufactured with the most appropriate method for its specific requirements.
Solution Approach 2:
Different manufacturing qualities are applied locally: the base master receives high-precision milling treatment, while the additional information carrier uses faster 3D printing. This local quality differentiation resolves the contradiction between speed and precision by matching the manufacturing method to the specific requirements of each segment.
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
This approach significantly reduces production time and cost by allowing for quick updates to additional print information, such as signatures or dates, without the need to recreate the entire master, thereby streamlining the production process for intaglio printing plates.
Implementation Method 1
A 3D printing process is used in a method for producing a printing plate containing a printed image for intaglio printing
Implementation Method 2
The master is converted into a matrix using a galvanic process
Data Source
Figure 1
Figure 2
AI summary
In a method for producing a printing plate (9) containing a printed image for intaglio printing, a 3D printing process is used. This can be done either by 3D printing the printing plate (9) itself, by 3D printing at least areas (4) of a matrix (5) from which the printing plate is molded, or by 3D printing at least parts of a master (1) from which a matrix (5) is produced for later duplication of the printing plate (9).