3D Toy Figure Inkjet Printing With Topographic Alignment
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Solution Overview
Problem
Existing inkjet printing methods for three-dimensional bodies, such as toy figure heads, face challenges with deformations caused by production processes like injection molding, leading to misaligned face decorations and high defect rates due to unpredictable shrinkage and inconsistencies.
Innovation Solution
An inkjet printing system that uses a metrology apparatus to create an updated body template based on topographical scanning, adjusting the fixture apparatus and ink application to accommodate deformations, ensuring precise alignment and consistent decoration by registering the front region of the three-dimensional body with the nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional inkjet printing methods are used on three-dimensional bodies produced by injection molding, then the printing process is simple and fast, but the deformations cause misaligned face decorations and high defect rates
Solution Approach 1:
The system performs topographical scanning and creates an updated body template before the inkjet printing process. This preliminary action captures the actual three-dimensional geometry of the printed body, allowing the printing design to be pre-adjusted to compensate for deformations that occurred during injection molding, thereby ensuring accurate alignment without sacrificing printing speed
Solution Approach 2:
The system uses topographical scanning to obtain feedback on the actual geometry of the three-dimensional body after injection molding. This feedback is used to generate an updated body template that reflects real deformations, which then guides the inkjet printing process to achieve precise placement of facial features despite the deformations
2Productivity
If injection molding is used to produce three-dimensional bodies, then production efficiency is high, but unpredictable shrinkage and inconsistencies cause deformations
Solution Approach 1:
Topographical scanning provides feedback on the actual dimensional variations and deformations that occur during injection molding. This feedback enables the system to create an updated body template that accurately reflects the real geometry, compensating for the unpredictable shrinkage and inconsistencies inherent in the injection molding process
Solution Approach 2:
The system changes the parameters of the body template based on topographical scanning data. By adjusting the template to match the actual deformed geometry, the system compensates for injection molding variations and ensures consistent, accurate printing across multiple production cycles
3Device complexity
If a fixed printing design is applied without accounting for deformations, then the printing process is simple, but the face decorations become misaligned
Solution Approach 1:
The system performs preliminary topographical scanning and generates an updated body template before applying the printing design. This preliminary adjustment of the template based on actual geometry ensures that facial features are correctly positioned, eliminating misalignment issues while keeping the actual printing process itself simple and automated
Data Source
AI summary
An inkjet printing system includes: a production apparatus configured to receive an original body template and to produce a three-dimensional body based on the original body template; a metrology apparatus configured to receive the produced three-dimensional body from the production apparatus and to topographically scan the received three-dimensional body to thereby produce an updated body template of the three-dimensional body; a control apparatus in communication with the metrology apparatus; and an inkjet printing apparatus. The control apparatus is configured to receive the updated body template and to create a topographical printing design based on the updated body template. The inkjet printing apparatus is in communication with the control apparatus, and is configured to receive the three-dimensional body and apply the created topographical printing design to the three-dimensional body.