UV Cure Control for 3D Printing on Transparent Media
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Solution Overview
Problem
Existing direct-to-shape (DTS) printing systems face challenges in applying images to transparent or semi-transparent media due to unpredictable UV light scattering, leading to printhead fouling and inconsistent image quality.
Innovation Solution
A process that utilizes a power scale factor to control UV energy application, optimizing ink curing by calculating a power scale factor applicable to partially cured ink layers and tailoring the final cure step to achieve optimal image quality on 3D objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional UV curing is used on transparent media, then ink curing is achieved, but UV light scattering causes printhead fouling and inconsistent image quality
Solution Approach 1:
The patent changes the power parameter of UV emitters dynamically. A power scale factor is calculated based on media transparency characteristics, and this factor is applied to adjust the power output of UV emitters during the curing process, transforming a static curing approach into a dynamic, adaptive one that accounts for UV scattering in transparent media
Solution Approach 2:
The patent implements a feedback mechanism where the actual curing results and UV scattering characteristics are measured, and this information is used to calculate and adjust the power scale factor for subsequent curing operations, creating a closed-loop control system that continuously optimizes curing parameters
2Reliability
If UV power is increased to ensure complete curing, then curing effectiveness improves, but printhead fouling increases due to UV scattering
Solution Approach 1:
Rather than uniformly increasing UV power, the patent calculates a power scale factor that optimizes the power distribution. This factor adjusts the power level to achieve complete curing while minimizing excess UV energy that would scatter and cause printhead fouling
Solution Approach 2:
The patent applies different power levels to different UV emitters or different regions of the curing process based on local requirements. The power scale factor enables localized power adjustment to ensure adequate curing where needed while reducing power in areas where scattering would cause harm
3Adaptability or versatility
If partial curing is used to allow multi-color printing, then printing flexibility improves, but additional curing steps are required increasing process complexity
Solution Approach 1:
The patent applies a preliminary partial cure using the power scale factor to stabilize the first color layer, enabling subsequent colors to be printed on top. This preliminary action prevents ink migration and ensures color accuracy while maintaining a relatively simple single-pass curing architecture
Solution Approach 2:
The curing process is divided into periodic stages: a first curing step with reduced power (using the power scale factor) for partial curing to enable color layering, and a second curing step to complete the curing process. This periodic action balances versatility with process simplicity
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
Precise control of UV energy ensures consistent and high-quality image application on transparent and semi-transparent media, reducing printhead fouling and improving production efficiency.
Implementation Method 1
curing of the expressed ink layer by application of a calculated amount of ultra-violet (UV) light energy
Data Source
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AI summary
A process is disclosed to precisely control the total amount of UV energy applied to images printed onto the exterior of a 3D object, such as a container like a wine bottle. The process includes establishing a UV dosage energy value to optimally cure an applied layer of ink expressed via an inkjet printing head onto the surface of the object, doing a partial cure of a printed ink layer, using a formula to calculate a power scale factor for the printed 3D object, and then based on the power scale factor tailoring a final cure step by controlling the amount of UV energy applied to the object to obtain an optimum cure result on the 3D object. The process allows for the control of a number of variables in the printing system to consistently apply an optimal amount of UV energy to the printed images.