Printing utilizing a virtual mask
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Solution Overview
Problem
Current three-dimensional printing systems face challenges in accurately printing designs on complex surfaces with varying geometries and irregularities, often resulting in inefficiencies and wastage of print materials due to the inability to differentiate between printable and non-printable areas.
Innovation Solution
The implementation of a sensor system and computing system that generate a virtual mask to classify areas on the printing surface as either print or no-print zones, allowing the printing system to selectively apply materials only to designated areas, thereby preventing unwanted printing on apertures and other non-tangible portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional three-dimensional printing systems are used to print on complex surfaces, then printing coverage is increased, but material waste increases and printing precision decreases
Solution Approach 1:
The printing surface is segmented into multiple zones using a virtual mask that distinguishes between printable areas and non-printable areas (such as apertures and irregular portions). This segmentation allows the printing system to selectively apply material only to designated zones, preventing waste on non-printable surfaces while maintaining precision on intended areas.
Solution Approach 2:
Different regions of the printing surface are assigned different properties through the virtual mask - some areas are designated as printable with full material application, while other areas are marked as non-printable with restricted or no material application. This local differentiation optimizes material usage and printing precision by adapting the printing process to the specific characteristics of each surface region.
2Quantity of substance
If printing is applied uniformly across the entire surface, then coverage is maximized, but material consumption increases
Solution Approach 1:
Instead of applying printing material uniformly across the entire surface, the system uses the virtual mask to implement partial action - applying material only to the extent necessary for printable areas. This reduces overall material consumption while maintaining printing efficiency on valid surfaces by avoiding unnecessary material application on non-printable regions.
3Manufacturing precision
If the printing system does not differentiate between printable and non-printable areas, then the process is simple, but printing accuracy deteriorates
Solution Approach 1:
A virtual mask is created as a digital copy or representation of the printing surface geometry, capturing the distinctions between printable and non-printable areas. This virtual model allows the printing system to differentiate surface regions without adding physical complexity to the printing apparatus, maintaining system simplicity while achieving high printing accuracy through software-based surface analysis.
Data Source
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.