Dimensional applique and methods of making and using the same

An apparatus for producing dimensional applique graphics, comprising:

• a printing system configured to deposit liquid photopolymer onto a substrate in successive layers to form a three-dimensional structure;
• an ultraviolet curing system positioned to cure each deposited layer of photopolymer immediately after deposition;
• and
• a cutting system comprising a cutting tool and positioned to receive the substrate after printing, the cutting system configured to separate individual dimensional appliques from the substrate based on pre-defined cut contour.

A method of manufacturing a dimensional applique, comprising:

• preparing a substrate with an adhesive layer configured to activate at a temperature below a degradation temperature of a cured photopolymer;
• depositing liquid photopolymer onto the substrate using a printing system to form a three-dimensional structure in successive layers;
• curing each deposited layer with ultraviolet light immediately after deposition;
• cutting the three-dimensional structure from the substrate using a precision cutting system aligned with registration fiducials formed as part of the three-dimensional structure;
• and
• removing the dimensional applique from the substrate for subsequent application to a target surface.