Printing utilizing a virtual mask
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Solution Overview
Problem
Current three-dimensional printing systems lack the ability to efficiently and accurately print designs on complex surfaces with varying areas, such as textiles, where certain regions need to be excluded from printing, leading to inefficiencies and potential damage to the substrate.
Innovation Solution
A method and apparatus that utilize a sensor system and computing system to create a virtual mask of the printing surface, classifying areas as either print or no-print zones, allowing the printing system to selectively apply materials only to designated areas, thereby preventing printing on prohibited regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional three-dimensional printing systems print on complex surfaces, then printing coverage is increased, but material waste increases and substrate integrity is compromised
Solution Approach 1:
The system performs preliminary scanning of the substrate surface using a sensor array to create a digital map identifying printable areas and non-printable areas before printing begins. This preliminary action allows the system to plan the printing path and material deposition strategy in advance, ensuring material is only applied to suitable areas and preventing waste on non-printable regions.
Solution Approach 2:
The virtual mask creates spatially varying printing properties across the substrate surface, designating specific regions as printable or non-printable based on local surface characteristics. This allows different areas of the substrate to have different printing permissions, enabling precise control over where material is deposited and preventing waste on areas where printing would be ineffective or damaging.
2Area of stationary object
If traditional printing systems print on complex surfaces, then design coverage is increased, but substrate damage increases
Solution Approach 1:
The sensor system scans and characterizes the substrate surface before printing to identify areas that are safe for printing and areas that would be damaged. This preliminary assessment creates a virtual mask that guides the printing system to avoid harmful regions while maximizing coverage on safe regions.
Solution Approach 2:
The virtual mask implements spatially differentiated printing permissions, allowing printing on robust areas of the substrate while prohibiting printing on fragile or sensitive areas. This local quality approach ensures that each region of the substrate is treated according to its specific properties, preventing damage while maintaining design coverage.
3Manufacturing precision
If virtual mask technology is implemented, then printing precision is improved, but system complexity increases
Solution Approach 1:
The system creates a virtual copy or digital representation of the substrate surface characteristics through scanning and processing. This virtual mask is a digital model that captures the essential features needed for precise printing control without requiring physical modifications to the printing hardware. The virtual mask serves as an intermediary layer between the digital design and physical printing process.
Solution Approach 2:
The patent replaces complex mechanical masking systems with a computational approach. Instead of using physical masks or complex mechanical positioning systems to control where printing occurs, the system uses software-based virtual masking that processes sensor data and generates printing instructions digitally, reducing mechanical complexity while maintaining or improving precision.
4Loss of substance
If selective printing on specific areas is implemented, then material efficiency is improved, but processing time increases
Solution Approach 1:
The system performs rapid scanning and virtual mask generation before printing to pre-determine the optimal printing areas. This preliminary action, while adding a step before printing, enables the printing process itself to be more efficient by avoiding unnecessary movements and material applications, ultimately reducing total processing time while improving material efficiency.
Solution Approach 2:
The sensor scanning and virtual mask generation are integrated into the overall printing workflow in a continuous manner. The system continuously gathers surface information and updates the virtual mask during the printing process, allowing seamless transition between scanning and printing operations without significant idle time, thus maintaining material efficiency while minimizing processing time overhead.
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.