Innovative solutions for rapid and cost-effective prototyping

Transcription

1 Innovative solutions for rapid and cost-effective prototyping by Alessandro Beltrami Glaze and colour producers, third fire ceramic tile producers and laboratories are experiencing a growing need to perform tile prototyping as part of their R&D activities and for small special production runs, such as those with precious metals. For these kinds of activities, normal single-pass digital decoration printers are often not sufficiently versatile, either due to their limited abil- ity to support multiple ink changes or simply because of quality issues deriving from the fixed transversal printhead resolution. For real prototyping or small just-intime production runs, certain activities need to be performed quickly, reliably and cost-effectively: Scanning of stone, wood and other natural materials Automatic colour management Plotter with quick ink change. Intesa s solution consists of three devices that can be combined perfectly to meet the needs of ceramic glaze and colour laboratories, third fire tile producers and companies wishing to prototype products without occupying lines and single-pass digital machines. IMAGO XL IMAGE SCANNER tion systems. It was created by adapting one of the best commercial optical systems on the market, produced by Seiko Epson, and fully exploits the system s ability to acquire details and colours on smooth and slightly textured materials. With an optical density of 3.8 DMax it can detect contrast on the most strongly variegated stone, while the native colour depth is 48bit. This means that it can acquire almost 300 trillion (3x1014) colour combinations compared to the 16 million colours of normal 8 bit per channel devices! Ceramic producers often require a spectral scanner, so let s look at Imago is a photographic scanner that acquires images of stone, wood and other flat materials without the need to break them into small pieces. Imago uses 2,400 dpi autofocus optics and is designed to reproduce colours and details with a high degree of accuracy so that they can be replicated with Intesa digital printers with the aid of the Crono colour management system. Its solid structure enables it to easily handle ceramic panels up to 1x1.5 metres in size and weighing up to 150 kg. The project was developed by Intesa with the goal of obtaining a robust and simple machine that would be easy to install and above all much less expensive than other acquisiwhy Imago may offer a valid alternative. A spectral scanner normally consists of a high-resolution camera but with a lower DPI than the native 2,400 of Imago. Filters are used to split up light solely across the visible spectrum (spectral scanner) or including part of the infrared and ultraviolet component (hyperspectral scanner). This means that the same device can acquire graphics and testcharts, whereas with an RGB scanner like Imago a spectrophotometer is required. The list of the pros and cons of Imago compared to a spectral scanner shows that it is difficult to make a direct comparison between the two devices: FIG. 1 - Imago - XL image scanner FIG. 2 - Imago - XL image scanner 22. Acimac handbooks Edition

2 Spectral scanner Imago Pros Cons Colorimetric precision Very high price. Light/shadow contrast not optimal. Low acquisition speed. Optics and lights produced in small quantities and difficult to find on the market. Need for custom software The price is a fraction of that of a spectral scanner. Maximum versatility and ease of use by any graphics operator. High acquisition speed (typically 15 min/m2 for 600 DPI high-quality scanning). Optics and lights produced for more than 15 years by Seiko Epson, which has customer support centres all over the world. Standard Epson software for PC and OSX. A spectrophotometer is required to complete the workflow From our experience at Intesa, we believe that a spectral scanner is not necessary in the ceramic industry. In all projects carried through using Imago (more than 100 in various factories), in the worst cases the same results were achieved as with the use of a spectral scanner. The ability to reproduce a material with precision, which is the key strength of a spectral scanner, becomes pointless if the designer has to make colour variations or perform graphic design processing. In this case, because Imago is a traditional RGB scanner it can generate a more versatile if theoretically less precise input file. CRONO DESKTOP 3 + SPECTROPRO CERAMIC COLOUR MANAGEMENT ly suitable for companies looking to start up digital ceramic production as it offers them a quick and simple way of achieving a good level of colour quality while minimising the number of trials required before commencing production. Crono manages ceramic colour in xclr mode, so it is in- Crono is a system developed by INTESA. Imaging since 2009 for colour management in the pre-printing stages of the digital decoration process. Crono software facilitates the use of digital images and of design and production data in the various processing stages. It is particulardependent of the CMYK model. This enables it to handle digital configurations with multiple colours (up to 8 or more), independently managing similar shades of colour on the machine. When interfaced with Imago and Colorscan 1010 it creates the ideal workflow for glaze and colour producers and for ceramic R&D laboratories. FIG. 3 - Crono Version 3 of the Crono system introduces an array of new features, all of which have been developed internally by the Intesa Imaging research centre. The main changes come from the new Crono Image Library which forms the basis of all new Intesa software: Crono Desktop, Crono Production, Crono Cap and the operational software of DHD and DHW digital machines. Crono Image Library allows images to be processed with stateof-the-art technology, using the multithread and video card resources to Acimac handbooks Edition. 23

3 FIG. 4 - Crono: image acquisition of marble and stone FIG. 5 - Crono: image acquisition of marble and stone speed up all operations. Improvements: Up to three times faster over a complete workflow compared to the previous version. Video preview and other operations optimised for processing Sacmi Continua and Continua+ line files. New CMYK and Multicolor profiler with proprietary mathematics and algorithms, compatible with 0/45 spectrophotometers (e.g. X-Rite EyeOne and Barbieri LFP) and d/8 sphere spectrophotometers (e.g. X-Rite SP62/64 and Konica Minolta CM 2500/2600d). The reliability and size limitations of the plug-in for Adobe Photoshop for Windows have been improved. Improved connection with Tecnografica database. Improved HotFolder function with halftoning capacity for complete automation of workflows with colour management and screening. Crono Image Library allocates computer resources intelligently to conserve RAM and to make maximum use of processors. Various strategies are used for small images or large sheets, including images larger than the computer s physical RAM. Auto Update function with automatic download and installation on request. New functions: Advanced Ink Saving workflow compatible with large profiles, with preview of results and information on savings. Complete management of PSD/ PSB and TIFF files with up to 11 alpha channels. Generation of test runs with automatic notes written on the tile. New Layout section with rotation, size change, cut and panelling functions; it is now possible to import a complete sheet and cut the sizes directly with Crono. Option with SpectroPro automated spectrophotometer to create perfect profiles on textured surfaces (e.g. Continua+ ) and tiles with finishing glazes and grits. Advanced manual change with Intesa Tone Compensation function and other utility tools. Plug-in for Adobe Photoshop for Apple OSX. Halftoning capacity with various algorithms and drop division parameters. Management of effects and white with levels sent separately to different machines (e.g. DH- D+DHW project in a single file). Creation of master files for Crono Production 3. FIG. 6 - Crono, profiling and separation FIG. 7 - Crono, advanced manual changes FIG. 8 - Crono, production preview 24. Acimac handbooks Edition

4 The Spectro Pro spectrophotometer is recommended for use in ceramic laboratories and glaze and colour factories. When a ceramic surface consists of glossy glazes, textures or finishes such as grits or protective glazes, it is very difficult for a normal 0 /45 spectrophotometer to read the colour accurately and repeatably. Incorrect measurements are detrimental to the generation of ICC profiles and impact on the entire Crono workflow, nullifying the benefits of soft proofing and adversely affecting image contrast. Spectro Pro is a Crono option for automating integrating sphere spectrophotometers, which are normally used in ceramic laboratories for formulating coloured glazes and for reading linearisations and testcharts in difficult measurement conditions. Crono Desktop can make use of readings made by sphere spectrophotometers in both SPIN mode and SPEX mode. FIG. 9 - Spectro Pro COLORSCAN 1010 CERAMIC PLOTTER Colorscan 1010 is a compact and versatile plotter, ideal for research, development and prototyping activities in the ceramic sector. The automation system consists of a Cartesian robot movement and ensures high printing precision. The movements of the X axis (carriage movement) and of the Y axis (table movement) are powered by linear motors. The Z axis movement (carriage up/ down) is managed by a stepper motor. The graphics program allows high-definition images to be printed in four-colour or multicolour mode. Colorscan 1010 can be equipped with a maximum of 8 colour modules with the option of a further 8 modules on stand-by for rapid ink changing. This means that up to 16 colour bars are available to simulate all the customer s ink combinations with a high degree of precision. The bars can be interchanged to perform sequence tests to be replicated on the single pass printer. Colorscan 1010 can operate in single pass emula- tion mode to reproduce the typical discharges of Xaar GS6 or GS12 printheads with multiple passes and achieve perfect, defect-free prototypes. For third fire production, Colorscan 1010 operates in high discharge mode, using multiple passes to deposit a greater quantity of colour than is possible in a normal single pass. These modes are managed using a special version of Crono Production, the software that functions as an RIP and adapts perfectly to the Crono Desktop graphic design firm workflow. FIG. 10 and 11 - Colorscan 1010 Acimac handbooks Edition. 25

5 GLAZING AND DECORATION IN THE DIGITAL AGE Intesa is continuing along its path of technological development with the goal of complete digitalisation of the ceramic glazing and decoration processes. For this purpose, it is unveiling a completely new range of digital printers marketed under the Sacmi brand name, demonstrating how its operations are becoming increasingly integrated with those of its Imola-based parent company. For inkjet printing, Intesa is proposing its DHD series of decorating machines based on technology from Xaar, the world leader in inkjet technology. The DHD series can be fitted with all types of Xaar 1002 printheads, including the brand new GS40 heads unveiled at Tecnargilla DHD printers offer a number of major improvements and innovations over previous versions of Intesa machines. In particular, the ink circulation and feeding systems have been entirely redesigned to ensure a very high level of performance. The electronics are also completely new. All Intesa machines now use proprietary electronics developed internally by the Sacmi Group, which ensure very high performance in terms of data transmission rates, manufacturing flexibility and reliability, while at the same time allowing for perfect integration between the various digital applications that are to be found today on a ceramic glazing and decoration line. Furthermore, the DHD printer management software has a simple and intuitive graphic interface that is easy to use by operators. The DHD digital printer range comprises models DHD708 (maximum printing width of 697 mm), DHD1108 (maximum width 1120 mm) and DHD1308 (maximum width 1390 mm). Alongside these models, which can be used to decorate all sizes up to 1200 mm after firing, Intesa is also proposing a digital printer version that has been specially designed for decorating very large format ceramic panels and for installation on Sacmi s Continua+ production lines. With its maximum printing width of 1882 mm and the possibility of installing up to 8 colour bars, the DHD 1808 has technical, construction and functional characteristics that are intended specifically for integration with the Continua+ production cycle. Equipped with an individual cleaning system for each colour bar, the DHD 1808 can be programmed to per- 26. Acimac handbooks Edition

6 form bar washing cycles in the time between the passage of one tile and the next, without the need to halt production. In view of the extraordinary benefits that digital technology offers for the decoration stage, the entire ceramic sector is striving to expand digital applications. In particular, special materials are being used to bring new aesthetic possibilities to the traditional decoration process, including increasingly rich natural textures, colours and effects. However, as these materials are still solvent-based and have a sub-micron particle size, they often have the drawback of high costs and limited application potential. To be able to produce tiles with the real material look and feel that cannot be achieved using inks alone, Intesa has developed the new HW printing technology for controlled application of ceramic glazes. HW technology can apply water-based glazes with particle sizes greater than 3 microns (range 3-12 micron). It is capable of depositing glazes in quantities of between 200 and 1000 grams per square metre for either full-field applications (engobes, textures) or specific spot applications integrated with traditional ink decoration. Initially designed and developed in the Sacmi Group s research laboratories, HW is now brought to the ceramic industry by Xaar with the brand new Xaar 001 printhead, featured on Intesa s Glazejet and DHW series digital printers. The Glazejet 330 laboratory plotter, complete with a printing station and DropWatcher system, has already been adopted by numerous glaze and colour producers for their glaze research and development activities. The Glazejet 1000 plotter is suitable for prototyping and developing large-size products. During Tecnargilla 2014, Intesa also unveiled the DHW 700 digital printer, the first single-pass digital machine for operation in a continuous industrial process. DHW can be synchronised with conventional inkjet printers and allows a fully digitalised glazing and decoration line to be created. NOTES Acimac handbooks Edition. 27