Printing utilizing a virtual mask
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Solution Overview
Problem
Current three-dimensional printing systems face challenges in efficiently and accurately printing on complex surfaces with varying geometries and materials, often resulting in inefficiencies and increased costs due to the need for extensive design adjustments and material wastage.
Innovation Solution
The implementation of a three-dimensional printing system that utilizes a virtual mask generated by a computing system to differentiate between print and no-print areas on an article, allowing for precise control of material deposition based on detected surface features, thereby avoiding unnecessary printing on apertures and other non-tangible portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional three-dimensional printing systems are used to print on complex surfaces, then printing coverage is increased, but material wastage increases and printing efficiency decreases
Solution Approach 1:
The system performs preliminary scanning of the article surface to detect apertures and non-tangible portions before printing begins. A virtual mask is generated in advance based on the scanned data, allowing the printing system to pre-identify areas that should not be printed on, thereby preventing material wastage before it occurs.
Solution Approach 2:
A virtual mask is introduced as an intermediary element between the printing system and the article surface. This virtual mask, generated from scanned aperture data, acts as a guide layer that directs the printing system to deposit material only on tangible portions, eliminating the need for physical masks or trial printing on apertures.
2Ease of manufacture
If traditional three-dimensional printing systems are used to print on complex surfaces, then printing coverage is increased, but design adjustment complexity increases
Solution Approach 1:
The printing system automatically scans the article surface, detects apertures, generates a virtual mask, and adjusts printing parameters without requiring manual design modifications. The system serves itself by autonomously adapting to the article's complex geometry, eliminating the need for designers to manually adjust designs for each unique article shape.
Solution Approach 2:
The system dynamically changes printing parameters based on real-time detection of surface features. By modifying printing behavior parameters (such as enabling or disabling material deposition in specific zones) based on detected aperture locations, the system adapts to complex surfaces without requiring complex design adjustments.
3Manufacturing precision
If printing is performed on all surfaces including apertures, then printing coverage is maximized, but printing precision decreases
Solution Approach 1:
The system applies different printing qualities to different regions of the article surface. By detecting apertures and generating a virtual mask, the system identifies specific local zones where printing should be excluded, allowing high-precision material deposition only on appropriate tangible portions while maintaining overall printing coverage on valid surfaces.
Data Source
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AI summary
A method for printing on an article is disclosed. An embodiment of a method may include receiving the article on a surface of a print system; receiving a print design for the article; forming a digitized image of the article using a sensor system; identifying one or more first portions of the article and one or more second portions of the article represented in the digitized image based on one or more detectable features on the surface of the article using a computing system, the first portion representing a print area of the article onto which a print material is to be printed and the second portion representing a no-print area of the article onto which the print material is not to be printed; forming a digital mask representing the second portion of the digitized image of the article and applying the digital mask to the print design to form a modified print design; and printing the modified print design on the article.