Designing a High-Speed Digital Printing Module for Conveyor and Roll-to-Roll Applications
Client Need & Project Overview
As high-volume printing environments evolved toward digital and on-demand production, Hewlett-Packard Specialty Printing Systems sought to develop a modular industrial inkjet system capable of integrating into a wide range of conveyor and roll-to-roll printing applications. The system needed to deliver high throughput, up to 400 feet per minute, while maintaining precision, reliability, and cost efficiency.
HP engaged NOVO Engineering to develop this industrial printing system, named VideoJet, to supplement their internal resources during a period of rapid project expansion. The goal was to create an adaptable, high-speed print module suitable for printing on books, envelopes, mailers, and other continuous media.
By combining industrial design principles with the cost-effective efficiencies of consumer-grade components, NOVO helped HP realize a production-ready platform that aligned with the company’s goal of developing modular digital printing systems.
Key Engineering Challenges & Solutions
| Challenge | NOVO’s Solution |
|---|---|
| Balancing Industrial Reliability with Consumer-Level Cost Targets The system needed to meet industrial durability standards while incorporating consumer-grade materials to control costs. |
Conducted design trade-off analysis to determine where machined metal components were essential and where injection-molded plastic parts could provide sufficient precision and strength. |
| Integration Across Diverse Media Systems The printer had to accommodate roll-to-roll, conveyor, and cut-sheet applications with varying motion and alignment requirements. |
Designed a modular print architecture with adjustable mounting features and synchronization options to match diverse material handling systems. |
| Printhead Precision and Maintenance Precise control of pen-to-paper spacing and automated maintenance cycles were required at high operating speeds. |
Integrated two precision-controlled motors, one for lateral service station movement and another for vertical printhead positioning, to maintain consistent print quality and enable automated servicing. |
| Ink Delivery at Industrial Scale Continuous, high-volume operation required reliable ink supply to multiple printheads. |
Developed an ink delivery module capable of supplying up to 1 liter of ink per hour to each printhead while maintaining consistent pressure and flow. |
Technical Innovations & System Design
NOVO’s engineers collaborated closely with HP’s internal team, providing on-site support and contributing half of the total development staff. Key design achievements included:
- Multi-Head Printing Architecture: Integrated four 0.85-inch printheads to achieve a total 4¼-inch print swath for monochrome printing at up to 400 feet per minute.
- Industrial-Grade Service and Maintenance System: Included a lateral-moving service station and a vertical-positioning mechanism to ensure proper spacing and long-term reliability.
- Adaptable Mounting System: Engineered mounting features for integration into both roll-to-roll and conveyor-based production lines.
- Durable, Cost-Optimized Construction: Used industrial-grade finishes and materials where necessary, while incorporating injection-molded plastics in non-critical areas to balance cost and robustness.
- Integrated Control and Monitoring: A PC-based operator interface provided control of print parameters and synchronized operation with external finishing equipment.
The result was a modular, application-independent print engine that could be adapted to a range of industrial systems, including high-speed book printing and direct mail production.
Results & Impact
- High Throughput Performance: Delivered up to 400 feet per minute print speed for large-volume production lines.
- Scalable System Architecture: Enabled integration across multiple printing and finishing configurations.
- Improved Engineering Efficiency: NOVO’s engineers contributed immediately upon engagement, accelerating development and reducing staffing costs.
- Operational Reliability: Designed for continuous-duty industrial environments with durable materials, robust drive systems, and high ink capacity.
A lead HP engineer commented, “This project was growing very uncontrollably… If we hadn’t contracted NOVO, I don’t know how we would have done it.”
Why NOVO Engineering?
The collaboration between HP and NOVO demonstrates how strategic outsourcing can accelerate innovation during rapid development cycles. NOVO’s multidisciplinary expertise in mechanical design, fluid systems, and industrial automation helped transform a complex engineering challenge into a scalable, cost-effective printing platform.
Modern modular print systems now incorporate IoT connectivity, predictive maintenance, and adaptive process control, continuing trends this project helped define by emphasizing modularity, system integration, and precision engineering.
Below is a video showing the VideoJet printhead mounted on a high-speed mail printing line.
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