Digital Printing System for Suitcase Design Distortion
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Solution Overview
Problem
Traditional methods for customizing suitcases and luggage items with rigid or semi-rigid materials face challenges such as high costs, distortion issues during the manufacturing process, and inflexibility in producing small runs with precise designs, leading to long manufacturing lead times and high design costs per product.
Innovation Solution
An in-line digital printing and drying system that allows for single-pass printing and customization of suitcases and luggage items, utilizing a traceability and tracking system, individual conveyors, and a printing module with CMYK or OGV ink lines, enabling precise control and versatility in design and color application without the need for additional molds or supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional engraving on plates or moulds is used during manufacturing, then designs can be incorporated on rigid or semi-rigid suitcases, but the designs become distorted when material is inflated by heat and deposited on the mould
Solution Approach 1:
The patent applies preliminary action by printing the design on the suitcase surface before the heat inflation process occurs. The digital printing is performed on the flat or pre-formed suitcase body, and the design is already in its final position before the material is heated and inflated over the mould. This ensures the design maintains its precision and does not become distorted during the forming process.
Solution Approach 2:
The patent inverts the traditional sequence by applying the design after the suitcase structure is formed rather than before. Instead of engraving the mould and having the design transfer during inflation, the system prints directly on the suitcase surface after it has taken its final shape, eliminating the distortion problem entirely.
2Adaptability or versatility
If traditional manufacturing systems with multiple colors are used, then complete designs can be created, but the costs per product become very high, especially for small production runs
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional subtractive color methods (engraving different colored layers) to digital additive color printing using CMYK or OGV ink systems. This allows for full-color designs with unlimited color variations without requiring additional manufacturing steps or molds for each color, dramatically reducing costs for small production runs while maintaining design versatility.
Solution Approach 2:
The patent uses digital copying technology where designs are stored as digital files and can be replicated indefinitely without additional tooling costs. Each suitcase receives a printed copy of the design from digital storage, eliminating the need for expensive physical molds or plates for each color combination, making small batch production economically viable.
3Reliability
If traditional methods with preparation and adjustment time are used, then quality control can be maintained, but the manufacturing lead times become very long, from fifteen days to one month per sample
Solution Approach 1:
The patent replaces the traditional mechanical system of manual preparation, adjustment, and molding with an automated digital printing system. The digital workflow allows for immediate printing of designs without manual setup or adjustment time, while quality control is maintained through digital precision and automated printing processes. This reduces manufacturing lead time from weeks to hours or minutes.
Solution Approach 2:
The patent applies preliminary action by preparing all design files and printing parameters in advance as digital data, eliminating the need for physical preparation and adjustment time. The digital designs are ready to print immediately, and the automated system requires no manual setup, allowing production to begin instantly and reducing lead times dramatically.
4Productivity
If in-line digital printing is used for customization, then production flexibility and speed are improved, but the system complexity increases with traceability and tracking requirements
Solution Approach 1:
The patent applies universality by designing an integrated system where the traceability and tracking components serve multiple functions: they identify each suitcase for correct design application, track production status, enable quality control, and facilitate inventory management. This multi-functional approach justifies the added system complexity by providing comprehensive control and flexibility that enhances overall productivity and customization capability.
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
The system enables efficient, cost-effective, and high-quality customization of suitcases and luggage items with precise control over design and color, reducing production time and costs, while ensuring minimal risk of damage during the printing process, thus meeting the demands for flexibility, precision, and speed in a dynamic market.
Implementation Method 1
The system further comprises a drying unit with UV ray generation devices configured to dry and fix the ink of the printed image
Data Source
AI summary
A system for stamping suitcases and luggage items, by in-line digital printing and drying, in a single pass, including: a printing module configured to print an image on one side of the suitcase with at least one printing head and one drying lamp; movement means for moving the items to be printed, with an individual conveyor belt, synchronised with the injector and the drying lamp, and movement means formed by a plurality of individual conveyors synchronised to operate according to the presence or absence of suitcases on adjacent conveyors, preventing them from impacting each other; and a traceability-tracking system configured to determine the position of each suitcase, by means of a unique two-dimensional identification code associated with each item, or by means of supervision of an operator. It also includes trays for coupling those suitcases that have an uneven shape, controlling the movement thereof and the correct alignment of the side to be printed.