Printing utilizing a virtual mask
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges in accurately printing designs on complex surfaces with varying structures, as they lack efficient methods to differentiate between print areas and non-print areas, leading to inefficiencies and potential damage to the surface.
Innovation Solution
The implementation of a method and apparatus that utilize a sensor system and computing system to classify areas on an object as either print areas or no-print areas through image capture and processing, generating a virtual mask to guide the printing process, ensuring that only designated regions receive print material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three-dimensional printing technologies are used on complex surfaces, then printing can be performed, but the system cannot accurately differentiate between print areas and non-print areas, leading to material waste and potential surface damage
Solution Approach 1:
The system performs preliminary scanning and classification of the surface into print and non-print areas before the actual printing process. This preliminary action allows the virtual mask to be generated in advance, guiding the printing system to only deposit material on designated areas, thereby preventing material waste and surface damage.
Solution Approach 2:
The patent introduces a virtual mask as an intermediary between the printing system and the complex surface. This virtual mask, generated from scanned surface data, acts as a guide that enables the printing system to accurately differentiate between print and non-print areas, solving the problem of material waste and imprecise printing on complex geometries.
2Ease of manufacture
If printing is performed on all surfaces without differentiation, then the process is simple, but material is wasted on non-print areas and surface damage may occur
Solution Approach 1:
The virtual mask serves as an intermediary that automatically differentiates print and non-print areas based on scanned surface geometry. This maintains process simplicity while protecting surface integrity, as the mask guides material deposition only to appropriate areas without requiring manual intervention or complex real-time decision-making.
Solution Approach 2:
The system uses feedback from the scanning process to generate the virtual mask, which then provides continuous guidance during printing. The feedback loop ensures that the printing system adapts to the actual surface geometry, preventing material waste and surface damage while maintaining operational simplicity.
3Manufacturing precision
If a virtual mask is generated through scanning and classification, then printing precision on complex surfaces is improved, but system complexity increases
Solution Approach 1:
The patent replaces complex mechanical masking systems with a computational approach. Instead of using physical masks or complex mechanical positioning systems, the invention uses software-based virtual masks generated from optical scanning data, thereby achieving high printing precision while reducing mechanical system complexity.
Solution Approach 2:
The system creates a digital copy (virtual representation) of the complex surface through scanning, then generates a virtual mask in this digital space. This copying approach allows precise printing guidance to be developed computationally without requiring complex physical systems, reducing overall device complexity while maintaining high precision.
4Productivity
If traditional printing methods are used without surface analysis, then the process is fast, but printing quality on irregular surfaces deteriorates
Solution Approach 1:
The system performs preliminary scanning and virtual mask generation before printing, enabling high-speed printing to proceed with pre-computed guidance. This preliminary action separates the complex analysis phase from the execution phase, allowing fast printing while maintaining high quality on irregular surfaces through the pre-generated virtual mask.
Data Source
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AI summary
A method and apparatus for printing on an article are disclosed. An embodiment of a method may include the generation of a virtual mask that can designate areas for printing and/or designate areas to exclude from printing. A method may include utilization of the virtual mask during either 2D or 3D printing such that a print design is printed in areas designated for printing by the virtual mask.