CA2614613A1 - Printed stone wall and method for printing images on a large non-uniform irregular planar surface - Google Patents
Printed stone wall and method for printing images on a large non-uniform irregular planar surface Download PDFInfo
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- CA2614613A1 CA2614613A1 CA002614613A CA2614613A CA2614613A1 CA 2614613 A1 CA2614613 A1 CA 2614613A1 CA 002614613 A CA002614613 A CA 002614613A CA 2614613 A CA2614613 A CA 2614613A CA 2614613 A1 CA2614613 A1 CA 2614613A1
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
- B44C5/00—Processes for producing special ornamental bodies
- B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J3/00—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed
- B41J3/407—Typewriters or selective printing or marking mechanisms characterised by the purpose for which they are constructed for marking on special material
- B41J3/4073—Printing on three-dimensional objects not being in sheet or web form, e.g. spherical or cubic objects
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/0041—Digital printing on surfaces other than ordinary paper
- B41M5/0047—Digital printing on surfaces other than ordinary paper by ink-jet printing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M5/00—Duplicating or marking methods; Sheet materials for use therein
- B41M5/0041—Digital printing on surfaces other than ordinary paper
- B41M5/007—Digital printing on surfaces other than ordinary paper on glass, ceramic, tiles, concrete, stones, etc.
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B3/00—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled substantially two- dimensionally for carving, engraving, or guilloching shallow ornamenting or markings
- B44B3/009—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled substantially two- dimensionally for carving, engraving, or guilloching shallow ornamenting or markings using a computer control means
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44B—MACHINES, APPARATUS OR TOOLS FOR ARTISTIC WORK, e.g. FOR SCULPTURING, GUILLOCHING, CARVING, BRANDING, INLAYING
- B44B3/00—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled substantially two- dimensionally for carving, engraving, or guilloching shallow ornamenting or markings
- B44B3/02—Artist's machines or apparatus equipped with tools or work holders moving or able to be controlled substantially two- dimensionally for carving, engraving, or guilloching shallow ornamenting or markings wherein plane surfaces are worked
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
- B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
- B41M7/00—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock
- B41M7/0072—After-treatment of prints, e.g. heating, irradiating, setting of the ink, protection of the printed stock using mechanical wave energy, e.g. ultrasonics; using magnetic or electric fields, e.g. electric discharge, plasma
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Ceramic Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Printing Methods (AREA)
Abstract
The invention relates to printed stonewall panels and method for 3D
reproduction of the image via 2D printing techniques onto a non-uniform irregular planar surface created via the transmission of the digitized 3D information to specific machineries onto a specified substrate. More precisely, an optical digital mean of interpreting the 3D
information from the photographic image associated with a numerically controlled engraving/milling machine (router) to transfer the images 3D elements onto a substrate associated with a high precision, large surface, printing machine combined with a high precision registration and positioning mean for printing the image on the engraved substrate to obtain an image with actual relief resulting in a 3D representation of the original photographic image.
reproduction of the image via 2D printing techniques onto a non-uniform irregular planar surface created via the transmission of the digitized 3D information to specific machineries onto a specified substrate. More precisely, an optical digital mean of interpreting the 3D
information from the photographic image associated with a numerically controlled engraving/milling machine (router) to transfer the images 3D elements onto a substrate associated with a high precision, large surface, printing machine combined with a high precision registration and positioning mean for printing the image on the engraved substrate to obtain an image with actual relief resulting in a 3D representation of the original photographic image.
Description
I DESCRIPTION
BACKGROUND OF THE INVENTION
TECHNICAL FIELD
The invention relates to printed stonewall panels and methods for the three-dimensional (3D) reproduction of the image via two-dimensional (2D) printing techniques onto a non-uniform irregular planar surface created via the transmission of said 3D information to specific machineries onto a specified substrate.
The invention also relates to a list of substrate materials that present specific physical and chemical attributes needed to support this invention.
Typical dimensions of the printed substrate range from a few square feet (few square meters) to over 500 square feet (50 square meters) covering external or internal applications.
BACKGROUND ART
A conventional technique to create the perception of 3D imagery on a 2D
support is to first print the image on a uniform planar surface then emboss the surface via mechanical means. This technique is widely covered by U.S. Publication No. US2003/0056885 and U.S.
Publication No. US2004/0261639 and more recently in U.S. Publication No.
US2005/0035488.
The regular & constant aspect of the non-planar surface allows to present in one axe the longitudinal displacement of the printing heads. This technique is covered by, U.S.
publication No. 2003/0001941 where the regular and constant non-planar object consists of a pre-embossed plastic card with a relatively small printing area.
Other techniques use mechanical means to rotate a uniform, non-planar object under the printing heads presenting a constant 2D surface to the printing heads.
U.S. patent No.
6,923,115 covers these techniques where the uniform, non-planar object consists of a sports ball of various dimensions.
A key feature of this invention is the method used to print on large non-uniform irregular planar surface. As presented above, previous inventions disclose techniques to print either on regular non-planar surfaces or uniform non-planar surfaces but not on large non-uniform irregular surfaces in both axes. PCT publication No. WO 02/18148 Al presents an apparatus to print on a non-planar and non-uniform surface, but restricted to only one axis.
No physical correlation between the image contour lines and the substrate relief exists.
For example, printing on a rough surface such as fabric does not require any physical correlation. Whereas in this new proposed process a highly precise correlation (called registration in the printing industry) is required between the printed image and it's non-planar substrate to emphasize on the 3D aspect of the product.
There is a growing need for printing large images on a substrate in relief.
For a one-time custom printing, the proposed process would use a numerically controlled milling machine (router) to engrave the relief into the substrate then print the image. None of the previously described techniques combine the retrieval and transmission of 3D
information from a photograph to an engraving process through printing techniques.
I For high speed printing, U.S. patent No. 6,460,958 covers nozzle design and angulations to print on 3D objects but does not address any registration techniques at any point in the patent. Similarly, U.S. patent No. 6,755,518 covers how the print heads may be independently moveable to control the spacing of the print heads from the substrate surface.
Whereas, as stated above, in this newly proposed process, a highly precise correlation is required between the printed image and it's non-planar substrate to emphasize the 3D aspect of the product. In addition, , this new proposed process uses motionless print head. Therefore no angulations or spacing adjustments are required.
For high volume, repeat-pattern printing of the engraved substrate is replaced by a pre-formed substrate manufactured in series. U.S. publication No. 2003/0001941 discloses a technique where the printed substrate consists of a pre-embossed plastic card.
There are a few issues with this pre-embossed plastic card: Firstly, this pre-embossed plastic card covers a much smaller printing surface than the techniques described in this invention.
Secondly the relief pattern is symmetric to the printing axis, which restricts considerably the relief pattern.
The proposed invention would support a much wider variety of relief patterns as well as of printing patterns.
SUMMARY OF THE INVENTION
The present invention seeks to eliminate or at least mitigate the disadvantages of the prior art and has for objective to provide a reproduction system of photographic images by interpreting the 3D information therein and then transferring the image and relief onto a substrate via data transfer process combined with machining processes and 2D
printing techniques results in a 3D, non-uniform, irregular, non-planar physical representation of the original photographic representation.
To this end, the printing system consists of:
- An optical mean of interpreting the three dimensional information from the photographic image.
- A numerically controlled engraving/milling machine (router) to transfer the elements of the image onto a substrate.
- A high precision, large surface, printing machine.
- A high precision registration and positioning means for printing the said image on the said engraved substrate.
All of which would result in a 3D representation of the original photographic image.
The engraving/milling machine will function by following the interpretation of the 3D
information produced in G-codes.
Additionally and/or alternatively, the engraved substrate may be used to receive the printed image or as a base to form a mould to reproduce identical in relief substrates. Each one would receive the printed image.
The selection of material for the said substrate will be chosen considering environmental conditions such as indoor/outdoor environment, proximity to a heat source (e.g. fireplace), 1 etc. Closed cell PVC foam board material has physical characteristics, which would meet these conditions.
Preferably, the printing equipment would utilize UV (Ultra-Violet) resistant ink and a UV
heat source that would rapidly cure the printing ink in order to prevent smudging and running of the ink on the slope area of the engraved substrate. To ensure complete &
proper ink coverage, all "slopes" should not exceed 75 degrees. The 3 axis flat bed printer would allow vertical displacement of the printing heads to accept different substrate thickness varying from {fraction 1/2) inch to {fraction I and 3/41 inches.
Preferably, the ink is 100% solid. The UV (Ultra-Violet) resistive ink is solvent free; in such is 100% solid.
Preferably the registration technique needed to line up the printed image with the engraved substrate should satisfy registration accuracy of less than {fraction 1/1281 inch (0.02mm) over a minimum surface area of 32 square feet (4 meter square). To ensure coarse registration, the image is first printed onto a transparency. The transparency is held in place from one edge then the substrate is slid under it and lined-up with the substrate. To ensure fine registration a clear layer with saturation of less than 10% is printed on the substrate.
Measurements are made in both axis (X,Y) to apply registration correction factors.
Various objects, features, aspects and advantages of the present invention will become clearer with the following description and accompanying drawings of a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates a simplified schematic of a first embodiment of the invention, specifically a system for printing the image of a stonewall panel via a 2D
printer onto an engraved substrate.
Figure 2 illustrates a representation of a system for printing the image of a stonewall panel via a 2D printer onto an engraved substrate.
Figure 3 is a flowchart representing the method for creating texture, specifically for stonewall panel.
Figure 4 illustrates a typical 3D printed stonewall.
Figure 5 illustrates a typical 3D printed door.
Figure 6 illustrates a typical 3D emblem.
Embodiments of the present invention are directed to printed stonewall and methods for their construction. Figure I shows a system for printing the image of a stonewall via a 2D
BACKGROUND OF THE INVENTION
TECHNICAL FIELD
The invention relates to printed stonewall panels and methods for the three-dimensional (3D) reproduction of the image via two-dimensional (2D) printing techniques onto a non-uniform irregular planar surface created via the transmission of said 3D information to specific machineries onto a specified substrate.
The invention also relates to a list of substrate materials that present specific physical and chemical attributes needed to support this invention.
Typical dimensions of the printed substrate range from a few square feet (few square meters) to over 500 square feet (50 square meters) covering external or internal applications.
BACKGROUND ART
A conventional technique to create the perception of 3D imagery on a 2D
support is to first print the image on a uniform planar surface then emboss the surface via mechanical means. This technique is widely covered by U.S. Publication No. US2003/0056885 and U.S.
Publication No. US2004/0261639 and more recently in U.S. Publication No.
US2005/0035488.
The regular & constant aspect of the non-planar surface allows to present in one axe the longitudinal displacement of the printing heads. This technique is covered by, U.S.
publication No. 2003/0001941 where the regular and constant non-planar object consists of a pre-embossed plastic card with a relatively small printing area.
Other techniques use mechanical means to rotate a uniform, non-planar object under the printing heads presenting a constant 2D surface to the printing heads.
U.S. patent No.
6,923,115 covers these techniques where the uniform, non-planar object consists of a sports ball of various dimensions.
A key feature of this invention is the method used to print on large non-uniform irregular planar surface. As presented above, previous inventions disclose techniques to print either on regular non-planar surfaces or uniform non-planar surfaces but not on large non-uniform irregular surfaces in both axes. PCT publication No. WO 02/18148 Al presents an apparatus to print on a non-planar and non-uniform surface, but restricted to only one axis.
No physical correlation between the image contour lines and the substrate relief exists.
For example, printing on a rough surface such as fabric does not require any physical correlation. Whereas in this new proposed process a highly precise correlation (called registration in the printing industry) is required between the printed image and it's non-planar substrate to emphasize on the 3D aspect of the product.
There is a growing need for printing large images on a substrate in relief.
For a one-time custom printing, the proposed process would use a numerically controlled milling machine (router) to engrave the relief into the substrate then print the image. None of the previously described techniques combine the retrieval and transmission of 3D
information from a photograph to an engraving process through printing techniques.
I For high speed printing, U.S. patent No. 6,460,958 covers nozzle design and angulations to print on 3D objects but does not address any registration techniques at any point in the patent. Similarly, U.S. patent No. 6,755,518 covers how the print heads may be independently moveable to control the spacing of the print heads from the substrate surface.
Whereas, as stated above, in this newly proposed process, a highly precise correlation is required between the printed image and it's non-planar substrate to emphasize the 3D aspect of the product. In addition, , this new proposed process uses motionless print head. Therefore no angulations or spacing adjustments are required.
For high volume, repeat-pattern printing of the engraved substrate is replaced by a pre-formed substrate manufactured in series. U.S. publication No. 2003/0001941 discloses a technique where the printed substrate consists of a pre-embossed plastic card.
There are a few issues with this pre-embossed plastic card: Firstly, this pre-embossed plastic card covers a much smaller printing surface than the techniques described in this invention.
Secondly the relief pattern is symmetric to the printing axis, which restricts considerably the relief pattern.
The proposed invention would support a much wider variety of relief patterns as well as of printing patterns.
SUMMARY OF THE INVENTION
The present invention seeks to eliminate or at least mitigate the disadvantages of the prior art and has for objective to provide a reproduction system of photographic images by interpreting the 3D information therein and then transferring the image and relief onto a substrate via data transfer process combined with machining processes and 2D
printing techniques results in a 3D, non-uniform, irregular, non-planar physical representation of the original photographic representation.
To this end, the printing system consists of:
- An optical mean of interpreting the three dimensional information from the photographic image.
- A numerically controlled engraving/milling machine (router) to transfer the elements of the image onto a substrate.
- A high precision, large surface, printing machine.
- A high precision registration and positioning means for printing the said image on the said engraved substrate.
All of which would result in a 3D representation of the original photographic image.
The engraving/milling machine will function by following the interpretation of the 3D
information produced in G-codes.
Additionally and/or alternatively, the engraved substrate may be used to receive the printed image or as a base to form a mould to reproduce identical in relief substrates. Each one would receive the printed image.
The selection of material for the said substrate will be chosen considering environmental conditions such as indoor/outdoor environment, proximity to a heat source (e.g. fireplace), 1 etc. Closed cell PVC foam board material has physical characteristics, which would meet these conditions.
Preferably, the printing equipment would utilize UV (Ultra-Violet) resistant ink and a UV
heat source that would rapidly cure the printing ink in order to prevent smudging and running of the ink on the slope area of the engraved substrate. To ensure complete &
proper ink coverage, all "slopes" should not exceed 75 degrees. The 3 axis flat bed printer would allow vertical displacement of the printing heads to accept different substrate thickness varying from {fraction 1/2) inch to {fraction I and 3/41 inches.
Preferably, the ink is 100% solid. The UV (Ultra-Violet) resistive ink is solvent free; in such is 100% solid.
Preferably the registration technique needed to line up the printed image with the engraved substrate should satisfy registration accuracy of less than {fraction 1/1281 inch (0.02mm) over a minimum surface area of 32 square feet (4 meter square). To ensure coarse registration, the image is first printed onto a transparency. The transparency is held in place from one edge then the substrate is slid under it and lined-up with the substrate. To ensure fine registration a clear layer with saturation of less than 10% is printed on the substrate.
Measurements are made in both axis (X,Y) to apply registration correction factors.
Various objects, features, aspects and advantages of the present invention will become clearer with the following description and accompanying drawings of a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 illustrates a simplified schematic of a first embodiment of the invention, specifically a system for printing the image of a stonewall panel via a 2D
printer onto an engraved substrate.
Figure 2 illustrates a representation of a system for printing the image of a stonewall panel via a 2D printer onto an engraved substrate.
Figure 3 is a flowchart representing the method for creating texture, specifically for stonewall panel.
Figure 4 illustrates a typical 3D printed stonewall.
Figure 5 illustrates a typical 3D printed door.
Figure 6 illustrates a typical 3D emblem.
Embodiments of the present invention are directed to printed stonewall and methods for their construction. Figure I shows a system for printing the image of a stonewall via a 2D
5 printer onto an engraved substrate.
As shown in figure 1, an optical digital I interprets the 3D information from a photographic image. A texture file 2 is generated based on the photographic image 1. A
print file 3 is generated based on the photographic image 1. The texture file 2 is used to generate the G-codes 4 in Type3 format. The print file 3 is used to prepare the file 5 for the printer in raster-scan. The G-codes 4 are sent to the numerically controlled engraving/milling machine (CNC) router 6 to engrave the substrate 8. The file 5 is sent to the high precision, large surface, flatbed printer 7 (the Inca's model, named "Columbia Turbo") to print the photographic image onto the engraved substrate 8 to obtain an image in relief resulting in a three dimensional representation of the original photographic image.
The preferred ink consists of 100% solids UV (Ultra-Violet) resistant ink and a UV heat source to rapidly cure the printing ink in order to prevent smudging and running of the ink on the sloped area of the engraved substrate. It is also within the scope of the invention for the ink to be solvent free, composed of 100% solids, such as SericolT"', the type manufactured by Fuji film.
As shown in figure 2, the printer head 9 is positioned 2.2 mm ({fraction 1/101 inch) above the highest point 10 of the substrate. The inkjet pattern 11 is set to ensure complete & proper ink coverage all "slopes" not to exceed 75 degrees 12. The maximum engraved thickness 13 is {fraction 1/4) inch for a maximum substrate thickness 14 of {fraction 1 and 3/41 inches.
For the purpose of this disclosure, a "substrate" material is defined as a material having a uniform composition throughout its area and depth, presenting one surface with engraved characteristics.
Figure 3 illustrates a flowchart representing the methods for creating texture for stonewall.
The bitmap generated in Photoshop 15 is imported in Type3. The substrate 16, comprising dimension X1,Y1,Z1 17 and reference points X0,Y0,Z0 18, is set. Generate in Type Art the solid surface 19 from the bitmap 15 using the following settings for stonewall;
white = 0 inch, black = -0.250 inch ({fraction -1/4} inch) and "linear lookup table" = "yes".
The white generates the highest relief points. The black generates the lowest relief points.
Setting the "linear lookup table" to -yes " allows the software to extrapolate all others relief points in a linear way between white and black. In this preferred case, a 50%
gray is set to a relief of -0.125 inch ({fraction -1/81 inch). Setting the "linear lookup table" to "no" allows the software to extrapolate all others relief points in a nonlinear way between white and black, whereas the nonlinear relation must be specified. Generate in Cam the G-codes 20. Engrave the relief on the substrate 16 using a ballnose endmill of 0.375 inch ({fraction 3/8) inch) diameter 21 and a stepover de 0.0937 inch. The stopover represents the spacing between each parallel pass.
Figure 4, the printed stonewall 22 is vertically self-supporting and can be moved and installed to any wall without the need of a reinforced backing. A"vertically self-supporting substrate"
is defined as a substrate with the ability to support its own weight when in a vertical configuration.
As shown in figure 1, an optical digital I interprets the 3D information from a photographic image. A texture file 2 is generated based on the photographic image 1. A
print file 3 is generated based on the photographic image 1. The texture file 2 is used to generate the G-codes 4 in Type3 format. The print file 3 is used to prepare the file 5 for the printer in raster-scan. The G-codes 4 are sent to the numerically controlled engraving/milling machine (CNC) router 6 to engrave the substrate 8. The file 5 is sent to the high precision, large surface, flatbed printer 7 (the Inca's model, named "Columbia Turbo") to print the photographic image onto the engraved substrate 8 to obtain an image in relief resulting in a three dimensional representation of the original photographic image.
The preferred ink consists of 100% solids UV (Ultra-Violet) resistant ink and a UV heat source to rapidly cure the printing ink in order to prevent smudging and running of the ink on the sloped area of the engraved substrate. It is also within the scope of the invention for the ink to be solvent free, composed of 100% solids, such as SericolT"', the type manufactured by Fuji film.
As shown in figure 2, the printer head 9 is positioned 2.2 mm ({fraction 1/101 inch) above the highest point 10 of the substrate. The inkjet pattern 11 is set to ensure complete & proper ink coverage all "slopes" not to exceed 75 degrees 12. The maximum engraved thickness 13 is {fraction 1/4) inch for a maximum substrate thickness 14 of {fraction 1 and 3/41 inches.
For the purpose of this disclosure, a "substrate" material is defined as a material having a uniform composition throughout its area and depth, presenting one surface with engraved characteristics.
Figure 3 illustrates a flowchart representing the methods for creating texture for stonewall.
The bitmap generated in Photoshop 15 is imported in Type3. The substrate 16, comprising dimension X1,Y1,Z1 17 and reference points X0,Y0,Z0 18, is set. Generate in Type Art the solid surface 19 from the bitmap 15 using the following settings for stonewall;
white = 0 inch, black = -0.250 inch ({fraction -1/4} inch) and "linear lookup table" = "yes".
The white generates the highest relief points. The black generates the lowest relief points.
Setting the "linear lookup table" to -yes " allows the software to extrapolate all others relief points in a linear way between white and black. In this preferred case, a 50%
gray is set to a relief of -0.125 inch ({fraction -1/81 inch). Setting the "linear lookup table" to "no" allows the software to extrapolate all others relief points in a nonlinear way between white and black, whereas the nonlinear relation must be specified. Generate in Cam the G-codes 20. Engrave the relief on the substrate 16 using a ballnose endmill of 0.375 inch ({fraction 3/8) inch) diameter 21 and a stepover de 0.0937 inch. The stopover represents the spacing between each parallel pass.
Figure 4, the printed stonewall 22 is vertically self-supporting and can be moved and installed to any wall without the need of a reinforced backing. A"vertically self-supporting substrate"
is defined as a substrate with the ability to support its own weight when in a vertical configuration.
The printed stonewall 22 iliustrated in figure 4 consists of a closed cell PVC
foam board. It is also within the scope of the invention for the substrate to be composed of this material, for example, the type known as SintraTM, manufactured by Alcan Composites. Such substrate has thermoplastic properties.
In this embodiment, the printed stonewall 22 may be approximately four feet wide, eight feet high, and {fraction 1/2} inch deep. However, it is also within the scope of the invention for the area of the sheets to be larger or smaller, depending on the need of the user. Thus, a printed stonewall 22 with a depth of between {fraction 1/2} and {fraction 1/4}
inch and an area of four square feet can be used for other application, like an emblem.
Preferably, the printed stonewall 22 is a nominal {fraction 3/4} inch deep, is vertically self-supporting and can be engraved with a router.
The printed stonewall 22 has an inside surface facing a construction wall, and an outside surface facing away from that wall.
A protective layer can be added to the outside surface of a printed stonewall 22 or between two adjacent printed stonewalls to improve its resistance and continuity between the two.
Although the invention is presented in terms of a printed stonewall, the embodiments are not intended to limit the scope to a stonewall, whereas the terms "stonewall'" can be replace with the term "door' 23 as show in figure 5 or replace with the term "emblem 24 as show in figure 6.
Although the foregoing describes the invention in terms of embodiments, the embodiments are not intended to limit the scope of the claims. Rather, the claims are intended to cover all modifications and alternative printing techniques falling within the spirit and scope of the invention, and are limited only by the plain meaning of the words as used in the claims.
foam board. It is also within the scope of the invention for the substrate to be composed of this material, for example, the type known as SintraTM, manufactured by Alcan Composites. Such substrate has thermoplastic properties.
In this embodiment, the printed stonewall 22 may be approximately four feet wide, eight feet high, and {fraction 1/2} inch deep. However, it is also within the scope of the invention for the area of the sheets to be larger or smaller, depending on the need of the user. Thus, a printed stonewall 22 with a depth of between {fraction 1/2} and {fraction 1/4}
inch and an area of four square feet can be used for other application, like an emblem.
Preferably, the printed stonewall 22 is a nominal {fraction 3/4} inch deep, is vertically self-supporting and can be engraved with a router.
The printed stonewall 22 has an inside surface facing a construction wall, and an outside surface facing away from that wall.
A protective layer can be added to the outside surface of a printed stonewall 22 or between two adjacent printed stonewalls to improve its resistance and continuity between the two.
Although the invention is presented in terms of a printed stonewall, the embodiments are not intended to limit the scope to a stonewall, whereas the terms "stonewall'" can be replace with the term "door' 23 as show in figure 5 or replace with the term "emblem 24 as show in figure 6.
Although the foregoing describes the invention in terms of embodiments, the embodiments are not intended to limit the scope of the claims. Rather, the claims are intended to cover all modifications and alternative printing techniques falling within the spirit and scope of the invention, and are limited only by the plain meaning of the words as used in the claims.
Claims (24)
1. A 3D printed stonewall panel comprises of:
i. A substrate associated with the entity presenting an irregular surface in the z-axis over a large planar x-y axis, and ii. Means for printing a plurality of digitized 3D stonewall pictures and correlating said digitized 3D stonewall pictures with known digitized substrate relief.
i. A substrate associated with the entity presenting an irregular surface in the z-axis over a large planar x-y axis, and ii. Means for printing a plurality of digitized 3D stonewall pictures and correlating said digitized 3D stonewall pictures with known digitized substrate relief.
2. A system according to claim 1, wherein the printing means is capable to derive from the 3D characteristic of the digitized 3D picture and associated digitized substrate relief a precise printing registration reference points.
3. A system according to claim 1, wherein the substrate is selected according to:
i. Limited deformation after milling to less than {fraction 1/16} inch over 12 inches;
ii. Present a white surface;
iii. Have a uniform density throughout all of its thickness;
iv. Mechanical stability over time;
v. Mechanical stability when exposed to extreme weather conditions;
vi. Fire retardant properties.
i. Limited deformation after milling to less than {fraction 1/16} inch over 12 inches;
ii. Present a white surface;
iii. Have a uniform density throughout all of its thickness;
iv. Mechanical stability over time;
v. Mechanical stability when exposed to extreme weather conditions;
vi. Fire retardant properties.
4. A system according to claim 1, wherein the UV ink is selected according to:
i. 100% solids;
ii. Viscosity;
iii. Light fastness;
iv. Wear resistance;
v. Adherence;
vi. Toxicity.
Where; Light fastness is defined as the resistance to fading over time due to UV rays or sunlight.
i. 100% solids;
ii. Viscosity;
iii. Light fastness;
iv. Wear resistance;
v. Adherence;
vi. Toxicity.
Where; Light fastness is defined as the resistance to fading over time due to UV rays or sunlight.
5. A system according to claim 1, wherein the parameters for the 3D printer are selected according to:
i. Characteristics of the relief in the z-axis;
ii. Dimensions in the x-y axis;
iii. Selected substrate;
iv. Selected ink.
i. Characteristics of the relief in the z-axis;
ii. Dimensions in the x-y axis;
iii. Selected substrate;
iv. Selected ink.
6. A 3D printing method, in accordance with the technique used in claim 1, wherein the steps of printing comprises the steps of:
i. Rendering a high-resolution picture to 3D printed surface;
ii. Creating texture;
iii. Creating a printing and engraving file;
iv. Constructing an in relief substrate;
v. Preparing the substrate surface;
vi. Defining the printing parameters;
vii. Verifying the registration accuracy;
viii. Printing the substrate;
ix. Applying a clear coat.
i. Rendering a high-resolution picture to 3D printed surface;
ii. Creating texture;
iii. Creating a printing and engraving file;
iv. Constructing an in relief substrate;
v. Preparing the substrate surface;
vi. Defining the printing parameters;
vii. Verifying the registration accuracy;
viii. Printing the substrate;
ix. Applying a clear coat.
7. A method according to claim 6, wherein step (i) means translating a high-resolution digitized picture into a digitized rendering of surface with low and high points.
8. A method according to claim 6, wherein step (ii) means creating a textured base on the pictured object.
9. A method according to claim 6, wherein step (iii) means creating a printing and engraving digitized file based on the pictured object.
10. A method according to claim 6, wherein step (iv) means selecting a substrate material based on the application while using a 3-axis router to engrave the relief.
11. A method according to claim 6, wherein step (v) means applying a first layer in order to stabilize the substrate and to present surface roughness to prevent the ink from sliding off abrupt edges. Abrupt edges are defined as edges exceeding 75 degrees.
12. A method according to claim 6, wherein step (vi) means defining the height of the printer head, the printing speed, the ultra-violet lamp intensity, number of layers and the saturation level.
13. A method according to claim 6, wherein step (vii) means verifying the registration accuracy by first printing a clear layer, second sliding the 3D surface under the transparency without moving said acetate, third aligning the 3D pattern with the pattern printed on the transparency, forth conducting a visual inspection and last applying registration corrections. Repeat until registration is accurate to less than {fraction 1/128} inches, (0.2mm).
14. A method according to claim 6, wherein step (viii) means selecting the ink and a flat bed printer using ultra-violet means for curing the ink.
15. A method according to claim 6, wherein step (ix) means applying manually a protective layer, whereas the said protective layer is a latex base clear coat.
16. A system according to claim 1, wherein the substrate is Sintra.TM. and wherein the digitized 3D picture represents a natural stonewall.
17. A method according to claim 16, wherein the steps for creating the texture use Photoshop and comprise the steps of:
i. Start with a white page layer, RGB mode and 100 dpi resolution;
ii. Set the filter to render clouds and colour to default;
iii. Add a second layer with mode set to lighten, opacity set to 50% and fill-up with white;
iv. Merge the two layers;
v. Add a third layer on top of the merged layers with mode set to darken, opacity set to 50%;
vi. Using a paintbrush with feathers set to 100% black, draw the mortar, whereas the said paintbrush diameter defines the width of the mortar, whereas the said feathers determine the angle at the edge of the stone;
vii. Save in a tiff file before merging the third layer;
viii. Merge the third layer with the previous two layers and save in Bitmap file to be able to import in Type3.
i. Start with a white page layer, RGB mode and 100 dpi resolution;
ii. Set the filter to render clouds and colour to default;
iii. Add a second layer with mode set to lighten, opacity set to 50% and fill-up with white;
iv. Merge the two layers;
v. Add a third layer on top of the merged layers with mode set to darken, opacity set to 50%;
vi. Using a paintbrush with feathers set to 100% black, draw the mortar, whereas the said paintbrush diameter defines the width of the mortar, whereas the said feathers determine the angle at the edge of the stone;
vii. Save in a tiff file before merging the third layer;
viii. Merge the third layer with the previous two layers and save in Bitmap file to be able to import in Type3.
18. A method according to claim 16, where the steps of printing and engraving comprise the steps of:
i. Open tiff file from claim 17;
ii. Delete all layers except the layer containing the grout pattern;
iii. Add a second layer underneath the layer with the grout pattern;
iv. Open pictures to be used as rocks on the current wall section;
v. Copy and paste the said rock pictures onto the newly created layer (behind the grout pattern). Erase any part that overflows from each rock as determined by the grout pattern;
vi. Merge all layers created by adding each individual rock pictures onto a single layer. Do not include the layer with the grout pattern;
vii. Load selection from grout pattern layer. Using the said selection, clear inside of selection on the layer with the rock pictures;
viii. Delete grout pattern layer;
ix. Add a new layer underneath the rocks picture layer and fill with image to be printed as grout;
x. Flatten image and save as tiff file;
xi. File is now ready to print.
i. Open tiff file from claim 17;
ii. Delete all layers except the layer containing the grout pattern;
iii. Add a second layer underneath the layer with the grout pattern;
iv. Open pictures to be used as rocks on the current wall section;
v. Copy and paste the said rock pictures onto the newly created layer (behind the grout pattern). Erase any part that overflows from each rock as determined by the grout pattern;
vi. Merge all layers created by adding each individual rock pictures onto a single layer. Do not include the layer with the grout pattern;
vii. Load selection from grout pattern layer. Using the said selection, clear inside of selection on the layer with the rock pictures;
viii. Delete grout pattern layer;
ix. Add a new layer underneath the rocks picture layer and fill with image to be printed as grout;
x. Flatten image and save as tiff file;
xi. File is now ready to print.
19. A system according to claim 12, wherein the printing parameters are defined as:
i. Printing head height: 2.2 to 2.5 mm minimum;
ii. Printing speed (V): 700 to 900 mm/second maximum for 75 degrees 350 to 400-mm/second maximum for 85 degrees;
iii. Ultra-Violet intensity: 6 amperes maximum for V = 900 mm/second 4.5 to 5 amperes maximum for V = 350 mm/second;
iv. Number of pass: 10 minimum;
v. Saturation: 2 x nominal Where:
mm are used for ease of representation, with 1 inch = 25.4 mm, Printing head height is the spacing between the highest point of the substrate and the bottom of the printing head, Ultra-Violet intensity is defined in terms of current consumption, Number of pass is defined as the number of printing layers for a raster image process, Saturation is defined in relation to the saturation level needed for a planar, meaning flat, surface. The saturation value increases with the porosity of the substrate.
i. Printing head height: 2.2 to 2.5 mm minimum;
ii. Printing speed (V): 700 to 900 mm/second maximum for 75 degrees 350 to 400-mm/second maximum for 85 degrees;
iii. Ultra-Violet intensity: 6 amperes maximum for V = 900 mm/second 4.5 to 5 amperes maximum for V = 350 mm/second;
iv. Number of pass: 10 minimum;
v. Saturation: 2 x nominal Where:
mm are used for ease of representation, with 1 inch = 25.4 mm, Printing head height is the spacing between the highest point of the substrate and the bottom of the printing head, Ultra-Violet intensity is defined in terms of current consumption, Number of pass is defined as the number of printing layers for a raster image process, Saturation is defined in relation to the saturation level needed for a planar, meaning flat, surface. The saturation value increases with the porosity of the substrate.
20. A method according to claim 17, wherein the steps for creating the texture use CorelDraw and Mastercam in replacement of Phtotoshop and Type3.
21. A method according to claim 17, wherein the steps for creating the texture use any other drawing software and formats.
22. A system according to claim 1, wherein the substrate is Sintra.TM. and wherein the digitized 3D picture represents a door.
23. A system according to claim 1, wherein the substrate is Sintra.TM. and wherein the digitized 3D picture represents an emblem.
24. A system according to claim 3, wherein the substrate is not engraved but is pre-formed and manufactured in high volume.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002614613A CA2614613A1 (en) | 2007-12-21 | 2007-12-21 | Printed stone wall and method for printing images on a large non-uniform irregular planar surface |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002614613A CA2614613A1 (en) | 2007-12-21 | 2007-12-21 | Printed stone wall and method for printing images on a large non-uniform irregular planar surface |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2614613A1 true CA2614613A1 (en) | 2009-06-21 |
Family
ID=40800532
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002614613A Abandoned CA2614613A1 (en) | 2007-12-21 | 2007-12-21 | Printed stone wall and method for printing images on a large non-uniform irregular planar surface |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2614613A1 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110696539A (en) * | 2019-09-27 | 2020-01-17 | 武汉工控艺术制造有限公司 | Manufacturing method of bronze ware artwork based on 3D printing |
| IT201900021651A1 (en) * | 2019-11-19 | 2021-05-19 | Carlo Rovatti | ROBOTIC DEVICE FOR DECORATION OF COVERING ELEMENTS FOR FLOORS, WALLS AND / OR CEILINGS AND RELATIVE SYSTEM AND PROCEDURE |
| WO2023143081A1 (en) * | 2022-01-27 | 2023-08-03 | 上海协承昌化工有限公司 | Wallboard substrate and direct printing wallboard using same |
-
2007
- 2007-12-21 CA CA002614613A patent/CA2614613A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN110696539A (en) * | 2019-09-27 | 2020-01-17 | 武汉工控艺术制造有限公司 | Manufacturing method of bronze ware artwork based on 3D printing |
| IT201900021651A1 (en) * | 2019-11-19 | 2021-05-19 | Carlo Rovatti | ROBOTIC DEVICE FOR DECORATION OF COVERING ELEMENTS FOR FLOORS, WALLS AND / OR CEILINGS AND RELATIVE SYSTEM AND PROCEDURE |
| WO2023143081A1 (en) * | 2022-01-27 | 2023-08-03 | 上海协承昌化工有限公司 | Wallboard substrate and direct printing wallboard using same |
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