Gantry based film applicator system

A masking system to apply a mask to a workpiece, comprising:

• a frame structure comprising a workpiece support, wherein the workpiece support is configured to maintain the location of the workpiece while the mask is applied to the workpiece;
• an application head configured to apply film to a workpiece to define the mask, wherein the mask is applied to an inside area of a surface of the workpiece and an unmasked perimeter region extends around the mask on the surface of the workpiece, wherein the application head comprises:
• a vacuum roller comprising a rotatable cylindrical body with an outer surface;
• a film roll comprising:
• a film wrapped around a spool,
• an unwind motor configured to rotate the spool, and
• a film roll diameter sensor configured to measure the diameter of the film roll,
• wherein the unwind motor has a variable unwind speed, wherein the unwind speed is adjusted to ensure a tension of an unwound film portion remains constant, wherein the unwind motor is configured to unwind film from the film roll at the same speed at which film is applied to the workpiece from the vacuum roller;
• a cutting element configured to cut the film to separate a portion of the film from a remainder of film on the film of the film roll, wherein the cutting element is arranged to cut the film on the vacuum roller, such that a cut end of the film connected to the film roll is maintained in a known location on the vacuum roller;
• a guide element disposed between the film roll and the vacuum roller, wherein the guide element is moveable, wherein the guide element is configured to contact an inner surface of the film to maintain a constant tension of the film between the film roll and the vacuum roller, wherein the guide element is configured to maintain a constant angular position of first contact between the film and the vacuum roller as the diameter of the film roll changes;
• and
• a wiper element arranged to follow the vacuum roller, such that the wiper element contacts film that has been applied to the workpiece;
• an X-axis movement element configured to move the application head relative to the frame structure along an X-axis;
• a Y-axis movement element configured to move the application head relative to the frame structure along a Y-axis;
• a Z-axis movement element configured to move the application head relative to the frame structure along a Z-axis;
• and
• a workpiece movement element configured to move the workpiece relative to the frame structure;
• wherein the x-axis movement element is configured to move the application head in a +x direction while applying the film to the workpiece,
• wherein after cutting the film on the vacuum roller, the z-axis movement element is configured to move the application head in a +z direction and the x-axis movement element is configured to move the application head further in the +x direction until the separated portion of film has been applied to the workpiece.