Laser cutting with feature location placement registration
A galvanometric laser for cutting and/or etching textile embellishments such as transfers or applique's and a method of operation thereof that is capable of visually capturing an incoming graphic image and referencing a cut pattern to the captured image and dynamically adjusting the cut pattern during cutting, etching and/or application of energy from the laser to thereby compensate for distortions in the fabric. The device includes a conveyor with an imaging station at which the graphic product is indexed under a high-resolution static camera with color recognition capability for the purposes of image capture. A high intensity bottoms-up light source resident at the imaging station provides ample illumination regardless of whether the design elements are face up toward the camera or face down toward the light source, or a combination of both. The system includes a computer at which the captured product image is analyzed, and the analytics are used to adjust the input cut file specifying the location and power settings for laser application. The product is then advanced in a controlled manner by means of the conveyor into a galvanometric cutting station where laser energy is applied. After completion the product is advanced out of the galvanometric cutting station for packaging.
1. A method of cutting and etching textiles having graphic elements thereon, comprising the steps of:
placing a graphic product on a conveyor;
conveying said graphic product on said conveyor to an imaging station;
illuminating said imaging station from beneath said conveyor;
imaging said graphic product as it sits atop said conveyor in the imaging station with high intensity bottoms-up light;
storing an RGB raster image file of said graphic product within a three-dimensional frame of reference;
inputting a separate cut file for laser cutting of said graphic product;
analyzing the stored RGB raster image file by feature-recognition software comprising computer instructions stored on non-transitory media for identifying an actual product feature within the RGB raster image file and an actual location of said identified product feature within said three-dimensional frame of reference, and adjusting said input cut file dynamically in registration to the actual location of said identified product feature within said three-dimensional frame of reference;
advancing said graphic product on said conveyor to a galvanometric laser cutting station;
applying laser energy to said graphic product in accordance with said adjusted cut file; and
advancing said graphic product out of the galvanometric cutting station on said conveyor for packaging.
2. The process according to claim 1 , wherein said conveyor is a belt conveyor.
3. The process according to claim 1 , further comprising a step of inputting a separate etch file for laser etching of said graphic product.
4. A galvanometric laser system for cutting and etching textile embellishments, comprising:
a continuous linear conveyor;
an imaging station along said conveyor;
a high-resolution color camera above the image station of said conveyor;
a high intensity bottoms-up light source beneath the imaging station of said conveyor;
a cutting station along said conveyor downstream of said imaging station;
a galvanometric laser cutting system for applying laser energy at said cutting station; and
a computer including a processor and non-transitory computer memory, and software stored on said computer memory for inputting a cut file for laser cutting of said graphic product, capturing an RGB raster image of said graphic product from said high-resolution color camera, analyzing said RGB raster image from said high-resolution color camera, identifying a feature of said RGB raster image relative to a frame of reference by feature-recognition, calculating an offset parameter based on a location of said identified feature within said frame of reference, and adjusting said input cut file dynamically by said offset parameter.
5. The galvanometric laser system according to claim 4 , wherein said continuous linear conveyor is a belt conveyor.
6. The galvanometric laser system according to claim 4 , wherein said high intensity bottoms-up light source comprises an LED array.
7. The galvanometric laser system according to claim 4 , wherein said computer is in communication with said galvanometric laser cutting system.