Patent ID: 7963628

Claim:
A method for forming a printed pattern from a pattern layout using a printing system, the printing system comprising a print head and a camera rigidly connected to the print head, the camera having an imaging sensor, the method comprising: performing a first alignment operation to achieve a specified orientation between the print head and a first set of alignment marks on a substrate using first image data generated by the imaging sensor of the camera; performing a first print operation after the first alignment operation to print a first portion of the pattern layout on the substrate to generate a first portion of the printed pattern, wherein performing the first print operation includes making a plurality of printing passes across the substrate in a first print direction; performing a second alignment operation to orient the print head relative to a second set of alignment marks on the substrate using second image data generated by the imaging sensor of the camera; and performing a second print operation to print a second portion of the pattern layout on the substrate to generate a second portion of the printed pattern, wherein performing the second print operation includes making a plurality of printing passes across the substrate in a second print direction that is non-parallel to the first print direction, wherein each of the set of alignment marks has an expected location, and wherein performing the first alignment operation comprises: measuring an actual location for each of the plurality of alignment marks; comparing the actual location for each of the plurality of alignment marks with the expected location for each of the plurality of alignment marks to determine an angle of rotation and translation vector; and utilizing the angle of rotation and translation vector to align the print head with the substrate.