Printable Blank Sheet with Run-Out Perforations for 3D Structures
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Solution Overview
Problem
Current die-cut templates for creating custom three-dimensional print materials are difficult to detach from excess sheets, often resulting in tearing and compromising the strength and image of the final structure due to irregular perforation placement and lack of weakening before separation.
Innovation Solution
A printable blank sheet with outline perforation lines and run-out perforation lines extending to the edges, allowing for easy detachment and folding along scored lines to form a three-dimensional structure, preventing unwanted tearing and ensuring a stronger final product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional die-cut templates with perforations are used, then the object can be defined and separated from the sheet, but the perforations are difficult to detach and often cause tearing of the object
Solution Approach 1:
The perforation lines are segmented into two distinct types: outline perforation lines that define the object boundary and run-out perforation lines that extend to the sheet edges. This segmentation allows the detachment process to occur along the run-out lines without compromising the integrity of the object defined by the outline perforations.
Solution Approach 2:
The run-out perforation lines are extracted as a separate functional element from the outline perforation lines. These run-out lines serve exclusively as detachment pathways, allowing the object to be removed from the sheet without requiring the outline perforations to bear the detachment stress, thereby preventing tearing.
2Adaptability or versatility
If perforations are placed irregularly to define the object shape, then the object can be customized, but the perforations cannot be easily folded and weakened before tearing
Solution Approach 1:
The perforation system is divided into outline perforations for shape definition and run-out perforations for detachment. The run-out perforations are specifically designed to be foldable and weakenable, providing a controlled detachment path that does not interfere with the irregular shape definition provided by the outline perforations.
Solution Approach 2:
The run-out perforation lines extend from the object boundary to the sheet edges, adding a dimensional pathway for detachment. This creates a separate detachment dimension that is independent of the object shape definition, allowing easy folding and weakening without compromising the customized shape.
3Ease of manufacture
If traditional die-cut templates are used, then the object can be created, but the process is costly and time-consuming requiring specialized machines and print shops
Solution Approach 1:
The printable blank sheet is designed to be self-sufficient, incorporating all necessary perforation patterns (outline and run-out) that enable the user to detach and assemble the object without specialized equipment. The sheet can be printed using standard office printers, and the run-out perforations allow easy manual detachment, eliminating the need for professional print shop services.
Data Source
AI summary
A printable blank comprises a sheet with a with outline perforation lines defining a periphery of an object. The sheet is capable of being passed through a printer to have an image printed on it. The sheet also comprises run-out perforation lines extending from the periphery to edges of the sheet, wherein the sheet can be folded along the run-out perforations to detach the object from the sheet. A method for creating custom print structures includes running a printable blank sheet through a printer and then bending the sheet along run-out perforation lines to detach an object from the sheet. The object can then be folded along scored fold lines to assemble it into a three-dimensional structure.