Abstract: A process is disclosed for creating a print profile to control the operation of a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The process takes a media recipe holding media geometry information and an image intended to be printed and processes that information to control a motion control subsystem and a print engine subsystem. The geometry information is manipulated to generate a CAM table suitable for the motion control subsystem, and the image file is processed to create a raster image file suitable for ink head expression. Various setup values are included in the process to prepare the direct-to-shape printing system for use of the media recipe.

Abstract: A method is disclosed to provide a DTS machine that is simple to operate and can through human operator control provide economic and competitive throughput speeds as compared to more complex DTS machines utilizing multiple printing tunnels and material handlers. The present method repositions a print carriage and a reconfigures an inkjet printhead bank to accommodate different sizes and shapes of media. The allows for the printing of a single piece of media in a single each printing event, but maintains a printing throughput similar to DTS machines having the capability to print media in parallel printing events. Media is moved from a media loading area on the machine by a single operator into a printing tunnel and then the operator adjusts the angle of the media relative to a reconfigurable array of ink-heads to meet inkjet expression distance requirements.

Abstract: A method is disclosed to provide a DTS machine that is simple to operate and can through human operator control provide economic and competitive throughput speeds as compared to more complex DTS machines utilizing multiple printing tunnels and material handlers. The present method repositions a print carriage and a reconfigures an inkjet printhead bank to accommodate different sizes and shapes of media. The allows for the printing of a single piece of media in a single each printing event, but maintains a printing throughput similar to DTS machines having the capability to print media in parallel printing events. Media is moved from a media loading area on the machine by a single operator into a printing tunnel and then the operator adjusts the angle of the media relative to a reconfigurable array of ink-heads to meet inkjet expression distance requirements.

Abstract: A system is disclosed to provide a DTS machine that is simple to operate and can through human operator control provide economic and competitive throughput speeds as compared to more complex DTS machines utilizing multiple printing tunnels and material handlers. The present invention utilizes a repositionable print carriage and a re-configurable inkjet printhead bank. The printing carriage is vertically positionable and tiltable, and includes a resizable spindle so that varying geometries of print media may be accommodated. The printer prints a single piece of media at each printing event, but maintains a printing throughput similar to DTS machines having the capability to print media in parallel printing events. Media is moved from a media loading area on the machine by a single operator into a printing tunnel and then the operator adjusts the angle of the media relative to a reconfigurable array of ink-heads to meet inkjet expression distance requirements.

Abstract: A process is disclosed for creating a print profile to control the operation of a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The process takes a media recipe holding media geometry information and an image intended to be printed and processes that information to control a motion control subsystem and a print engine subsystem. The geometry information is manipulated to generate a CAM table suitable for the motion control subsystem, and the image file is processed to create a raster image file suitable for ink head expression. Various setup values are included in the process to prepare the direct-to-shape printing system for use of the media recipe.

Abstract: A process is disclosed for creating a print profile to control the operation of a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The process takes a media recipe holding media geometry information and an image intended to be printed and processes that information to control a motion control subsystem and a print engine subsystem. The geometry information is manipulated to generate a CAM table suitable for the motion control subsystem, and the image file is processed to create a raster image file suitable for ink head expression. Various setup values are included in the process to prepare the direct-to-shape printing system for use of the media recipe.

Abstract: A system is disclosed that provides a compact printing system for applying images on the exterior of a clear or semi-transparent 3-dimensional object, such as for example a clear container like a wine bottle. The printing system includes a shuttle system for transporting a grouped parallel series of blank 3D media simultaneously into a printer portion of the system for parallel printing of media. The printer includes a series of printing tunnels that control a novel arrangement of print heads, pinning lamps, and a final cure lamp that minimizes or eliminates the chances for stray UV light to potentially impinge upon and foul inkjet printing heads used to express ink onto the surface of the 3D media. The arrangement allows for a higher degree of throughput of 3D media while avoiding the prior problems of the fouling of printheads during the printing of images on transparent or translucent media.

Abstract: A process is disclosed to precisely control the total amount of UV energy applied to images printed onto the exterior of a 3D object, such as a container like a wine bottle. The process includes establishing a UV dosage energy value to optimally cure an applied layer of ink expressed via an inkjet printing head onto the surface of the object, doing a partial cure of a printed ink layer, using a formula to calculate a power scale factor for the printed 3D object, and then based on the power scale factor tailoring a final cure step by controlling the amount of UV energy applied to the object to obtain an optimum cure result on the 3D object. The process allows for the control of a number of variables in the printing system to consistently apply an optimal amount of UV energy to the printed images.

Abstract: A method is disclosed for reducing the scatter of UV light during a final curing operation in the three-dimensional printing on the surface of transparent and semi-transparent media. The method precisely controls the movement of media during a final cure step in the printing of an expressed inkjet image on the surface of transparent media. The method also controls a number of factors during final curing operation such as the lateral movement of media under a final cure lamp, the number of rotations that media undergoes during final curing, the timely modulation of UV lamp power during final curing, and the selection of UV emitter segments positioned away from a inkjet print head to reduce the amount of potential UV radiation from impinging upon one or more of the adjacent printing heads.

Abstract: A printing and partial curing process for 3D objects that avoids print fouling due to scattered UV light. The process uses the steps of expressing an image from an inkjet printing head onto the surface of a rotating piece of transparent media, rotating the media surface along a single rotational axis away from the inkjet printing head to allow full wetting of an expressed image onto the media surface, and further rotating the media surface so that the expressed image enters a shaped ultraviolet illumination beam field that causes the partial curing of the image so that said image is held in place on the surface during continued rotation as additional ink is applied to the surface. The partial curing or “pinning” lamp is precisely positioned so that ultraviolet beam field avoids impinging on the inkjet print heads so that fouling does not occur.

Abstract: An inkjet print head assembly and a method of using the assembly is disclosed for applying images on the exterior of an axially symmetrical media object that has a varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The printing assembly includes a backing plate, a pair of independently extendable extension columns, and a print head on a platform depending downward from said columns. The assembly is supported by the frame of the printer and a movable carriage moves the media object from a loading area into a printing area near the printing assemblies where the assemblies may apply ink to the exterior of the media object. Each print head is movable in 3-dimensions such that as the media object moves under each head the print head tilts to match to local slope of the contoured surface underneath the ink jetting nozzles.

Abstract: An ink pressure modulation method is presented in a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The method varies ink pressures based on the movement positions of each print head as they move over the surface of the media object. A movement-based formula is presented to allow for continuous updating of pressures in ink tank manifolds to allow independent changes in pressure to each inkjet print head during printing.

Abstract: A turret styled container decorator machine is disclosed having a rotatable turret and a number of circumferentially spaced container holding assemblies for holding a variety of pieces of media, such as a drink container, the surface of which is to be printed upon with an image. A plurality of workstations are positioned around the perimeter of the turret through which each media holder passes as the turret rotates. Each workstation includes an ink printing assembly and a curing assembly so that ink may be applied and cured as each piece of media is indexed into each workstation location. Each printing workstation may be removed and replaced with a different arrangement or configuration of ink heads to suit different types of media sizes and shapes, and the turret holds a plurality of media holding means assigned to a pie-shaped section of the turret adjustable to accommodate various types of media geometries.

Abstract: The invention is a method of using a turret styled decorator machine to decorate container media. The machine utilized has a rotatable turret and a number of circumferentially spaced container holding assemblies for holding a variety of pieces of “media,” such as a drink container, the exterior surface of which is to have ink applied to form an image. A plurality of workstations are positioned around the perimeter of the turret through which each media holder passes as the turret rotates. Due to the unique configuration of the decorating machine, each piece of media, once loaded, spins at a rate different from any other piece of media so that the entire decorating process is speed optimized for each print job. Further, container media may spin continuously during the decorating process so that the turret never needs to pause for media to stop rotating or to begin rotating.

Abstract: A process is disclosed for creating a print profile to control the operation of a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The process takes a media recipe holding media geometry information and an image intended to be printed and processes that information to control a motion control subsystem and a print engine subsystem. The geometry information is manipulated to generate a CAM table suitable for the motion control subsystem, and the image file is processed to create a raster image file suitable for ink head expression. Various setup values are included in the process to prepare the direct-to-shape printing system for use of the media recipe.

Abstract: An ink pressure modulation method is presented in a direct-to-shape printing system for applying images on the exterior of an axially symmetrical media object that has a contoured, varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The method varies ink pressures based on the movement positions of each print head as they move over the surface of the media object. A movement-based formula is presented to allow for continuous updating of pressures in ink tank manifolds to allow independent changes in pressure to each inkjet print head during printing.

Abstract: An inkjet print head assembly and a method of using the assembly is disclosed for applying images on the exterior of an axially symmetrical media object that has a varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The printing assembly includes a backing plate, a pair of independently extendable extension columns, and a print head on a platform depending downward from said columns. The assembly is supported by the frame of the printer and a movable carriage moves the media object from a loading area into a printing area near the printing assemblies where the assemblies may apply ink to the exterior of the media object. Each print head is movable in 3-dimensions such that as the media object moves under each head the print head tilts to match to local slope of the contoured surface underneath the ink jetting nozzles.

Abstract: A printing system applies images on the exterior of an axially symmetrical object that has a varying exterior surface, such as occurs on curved wine bottles and sports equipment like bats. The printing system includes a movable carriage having rotatable locking end members for holding the object for printing stationary along its longitudinal axis, but allowing for controlled rotation of the object. The carriage moves the object from a loading area into a printing area and a plurality of movable printing head assemblies position a plurality of ink jet heads over the surface of the object as it is moved along a linear axis under the print head assemblies. Each print head is movable such that as the object moves underneath the print head tilts to match the local slope of the contoured surface as ink is being applied. The applied image is then cured with UV lamps during rotation.