3D Printed Watermark Tool Laser Remelt Polishing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current 3D-printed injection molding tools for producing high-resolution watermark inserts face challenges due to their rough surface, making demolding difficult and leading to bubbles in the dewatering screen, which requires additional processing steps and precise positioning for post-treatment.
Innovation Solution
A method involving 3D printing a tool blank with a high-resolution multi-stage watermark relief, followed by laser remelt polishing to smooth the surface, ensuring positional accuracy and integrating unevenness, allowing for the creation of a high-resolution injection molding cavity suitable for producing watermark sets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If 3D printing is used to produce injection molding tools, then high-resolution watermark relief can be achieved, but the surface becomes rough causing demolding difficulties and bubbles
Solution Approach 1:
The patent applies preliminary action by performing laser remelting polishing on the 3D-printed tool blank before actual injection molding. This pre-treatment smooths the rough surface and integrates material unevenness, preventing demolding issues and bubbles in the final product. The surface is prepared in advance to eliminate defects that would otherwise compromise reliability.
Solution Approach 2:
The patent changes the physical state and surface parameters of the tool blank through laser remelting. The laser energy alters the surface morphology by melting and re-solidifying the material, transforming the rough 3D-printed surface into a smooth, dense surface suitable for high-quality demolding and injection molding.
2Manufacturing precision
If post-treatment is applied to smooth 3D-printed molds, then surface quality improves, but additional processing stations and positioning requirements increase complexity
Solution Approach 1:
The patent merges the 3D printing device with laser remelting functionality into a single integrated system. The 3D printing device includes both the additive manufacturing module and the laser remelting module, allowing both construction and surface smoothing operations to be performed in one location. This eliminates the need for separate processing stations and reduces positioning complexity.
Solution Approach 2:
The 3D printing device is designed with multi-functionality, serving both as an additive manufacturing system and as a laser remelting system. The same device performs multiple functions: building the tool blank layer by layer and subsequently smoothing its surface through laser remelting, thereby reducing overall system complexity.
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
This method enables the production of high-resolution watermark inserts with improved surface smoothness and accuracy, overcoming demolding issues and enabling precise transfer of high-resolution data, thus enhancing the production of watermark tools with superior properties.
Implementation Method 1
a tool blank with the watermark relief determined in step B) is produced in a 3D printing device by layer-by-layer application and selective solidification of a build-up material
Implementation Method 2
the tool blank is polished by laser exposure after step E) in the same 3D printing device in a positionally accurate manner in order to smooth the produced watermark relief
Data Source
Figure 1~3(a)
Figure 3(b)~3(d)
Figure 3(e)~3(g)
AI summary
The invention relates to a method for manufacturing a watermark tool (30) with an injection molding cavity (56) provided with a high-resolution, multi-stage watermark relief (54) and into which plastic can be injected to produce a watermark set, wherein in the method V) a desired high-resolution, multi-stage injection molding relief (22) is specified for the watermark set (20), B) a corresponding high-resolution, multi-stage watermark relief (54) is determined from the specified injection molding relief (22) for (56) producing the specified injection molding relief, E) a tool blank (84) with the watermark relief (54) determined in step B) is produced in a 3D printing device (60) by layer-by-layer application and selective solidification of a build-up material (70), G) the tool blank (64) is polished by laser treatment after step E) in the same 3D printing device (60) in a positionally accurate manner.to smooth the generated watermark relief (54), and W) the polished tool blank (40) is further processed into a watermark tool (30), wherein the watermark relief smoothed in step G) forms the high-resolution, multi-stage watermark relief of the injection molding cavity (56) of the watermark tool (30). The invention also relates to an associated device for producing a watermark tool with an injection molding cavity.