Print Profile Control for Contoured Axially Symmetric Objects
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Solution Overview
Problem
Existing direct-to-shape (DTS) printing systems struggle to produce high-quality images on axially symmetrical objects with contoured exteriors, such as curved bottles and sports equipment, due to non-optimal printhead positioning that leads to ink drop drift and overspray, limiting the types of media that can be printed.
Innovation Solution
A process for creating a print profile that controls the operation of a DTS printing system by manipulating media geometry information and image data to generate a CAM table, adjusting printhead movements, and applying a gradient mask to ensure consistent ink application on contoured surfaces, using a combination of software and hardware components to maintain precise ink deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional DTS printing systems use fixed printhead positioning, then the printing process is simple to operate, but ink drop drift and overspray occur on contoured surfaces
Solution Approach 1:
The printhead positioning system transitions from fixed to dynamic adjustment, allowing the printhead to move along the axial direction of the rotating object. This dynamic positioning enables the printhead to maintain optimal distance from the contoured surface during rotation, preventing ink drop drift and overspray while adapting to varying surface geometries
Solution Approach 2:
The system incorporates feedback control where the position of the printhead is continuously adjusted based on the rotation angle and surface contour of the object. This feedback mechanism ensures precise ink drop placement by compensating for surface variations in real-time during the printing process
2Manufacturing precision
If the printhead is positioned closer to the object surface, then ink application precision improves, but ink drop drift and overspray increase on contoured surfaces
Solution Approach 1:
The printhead positioning system transitions from fixed to dynamic adjustment, allowing the printhead to move along the axial direction of the rotating object. This dynamic positioning enables the printhead to maintain optimal distance from the contoured surface during rotation, preventing ink drop drift and overspray while adapting to varying surface geometries
Solution Approach 2:
The system applies different printhead distances locally across the surface being printed. By adjusting the printhead position dynamically according to the local contour geometry, the system maintains optimal printing conditions for each specific area, reducing ink drop drift and overspray while preserving precision
3Adaptability or versatility
If DTS printing is used to print on various contoured objects, then printing flexibility increases, but ink deposition consistency deteriorates
Solution Approach 1:
The printhead positioning system transitions from fixed to dynamic adjustment, allowing the printhead to move along the axial direction of the rotating object. This dynamic positioning enables the printhead to maintain optimal distance from the contoured surface during rotation, preventing ink drop drift and overspray while adapting to varying surface geometries
Solution Approach 2:
The system dynamically changes the printhead position parameter during the printing process based on the object's rotation angle and surface contour. This parameter adjustment ensures consistent ink deposition by compensating for variations in surface geometry, maintaining uniform ink transfer across different contoured shapes
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 high-quality printing on axially symmetrical objects with varying contours by minimizing ink drop misalignment and overspray, allowing for consistent image density and improved print quality on complex shapes.
Implementation Method 1
Inkjet printing utilizes a digital printhead to print full color customized designs in one or multiple imaging passes and may be applied directly to the substrate surface of the object. The transfer occurs by propelling droplets of ink directly onto the substrate medium.
Implementation Method 2
The ink is either partially or fully cured immediately after printing by exposing the ink to an energy-emitting means, such as a UV light emitter, positioned directly beneath the object.
Data Source
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AI summary
A process is disclosed for creating a print profile to control the operation of a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The process takes a media recipe holding media geometry information and an image intended to be printed and processes that information to control a motion control subsystem and a print engine subsystem. The geometry information is manipulated to generate a CAM table suitable for the motion control subsystem, and the image file is processed to create a raster image file suitable for ink head expression. Various setup values are included in the process to prepare the direct-to-shape printing system for use of the media recipe.