Engineered to deliver reliable high-speed media handling, precise vacuum control, and scalable transport performance for next-generation industrial printing systems
A manufacturer of industrial digital printing systems was developing a next-generation single-pass inkjet printer and required a high-speed transport system capable of handling a wide variety of media types while maintaining precise positioning and reliable throughput.
The new platform needed to transport materials including corrugated cardboard, MDF, plywood, cardstock, and other substrates at speeds up to 150 meters per minute, nearly four times faster than previous systems. At the same time, the transport platform had to accommodate media ranging from 0.6 to 1.8 meters wide and between 1 and 50 millimeters thick while integrating seamlessly into an existing printer architecture with strict mechanical and controls constraints.
The project timeline added another layer of complexity. The system was being developed for introduction at drupa, the world’s largest printing technology exhibition, which occurs only once every four years. Missing the event was not an option, creating significant schedule pressure for design, fabrication, testing, and deployment.
The client partnered with Re:Build DAPR to develop a high-performance transport platform capable of meeting aggressive speed, flexibility, and delivery requirements while supporting future printer development initiatives.
Re:Build DAPR worked closely with the client’s engineering and fabrication teams to define system requirements and develop a transport solution capable of supporting both current and future printer platforms.
A major focus of the project involved evaluating vacuum transport performance, media stability, and belt tracking behavior at elevated operating speeds. Engineering teams analyzed transport dynamics, vacuum requirements, structural loading conditions, and system stiffness to ensure reliable operation across a broad range of substrate materials and sizes.
The team utilized Mathcad calculations for vacuum and motor sizing while performing Finite Element Analysis (FEA) to validate structural integrity, vibration characteristics, and overall machine performance. Multiple belt materials were evaluated to assess tracking performance, stiffness, durability, and compatibility with varying media types.
Because of the compressed development schedule, close coordination between Re:Build DAPR, the client, and external suppliers was critical throughout design, fabrication, assembly, and testing activities to ensure successful delivery ahead of the Drupa deadline.
Re:Build DAPR designed and delivered three custom vacuum belt transport systems optimized for high-speed industrial printing applications.
At the core of each system was a variable-width vacuum transport platform engineered to maintain precise media control across a wide range of substrate sizes and materials. The transport architecture was designed to operate at speeds up to 150 meters per minute while maintaining stable tracking, consistent vacuum performance, and reliable conveyance through the printer.
Engineering analysis played a critical role in the development process. Mathcad was used to size motors and vacuum systems, while Finite Element Analysis (FEA) validated structural performance and vibration characteristics under demanding operating conditions. The team also evaluated multiple belt materials and validated the client’s preferred polyester mesh belt to optimize stiffness, tracking performance, and long-term reliability.
To meet aggressive project timelines and integration requirements, the transport systems were designed around the client’s existing printer architecture while simplifying assembly, maintenance, and future upgrades. Close collaboration between Re:Build DAPR, the client’s engineering team, and fabrication partners ensured the systems were delivered and commissioned in time for a successful product launch at Drupa.
Re:Build DAPR successfully delivered all three transport systems on schedule, enabling the client to showcase its next-generation printing technology at Drupa.
Performance testing validated the transport architecture, vacuum control strategy, and media handling approach across a wide range of substrates and operating conditions. The successful deployment demonstrated the viability of the client’s new printing platform while providing a robust foundation for future product development and commercialization.
Beyond the initial system delivery, the project established a strong engineering partnership between Re:Build DAPR and the client. The success of the transport platform led directly to multiple follow-on projects, including vacuum belt system enhancements, printer enclosures, media stacking systems, and custom conveyor development efforts.
The completed platform provided the client with a scalable transport solution capable of supporting future printer generations while reducing development risk through proven engineering, testing, and validation.
The transport system includes:
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