DPI Laboratory Introduces VisionAI to Bring Intelligence to UV Production

KEY TAKEAWAYS

• DPI introduces VisionAI for UV printing: DPI Laboratory launches Catalyst VisionAI, a camera-based positioning system for automated UV print alignment and setup.
• Smart production tools continue expanding: Integrated AI and machine vision systems are becoming increasingly important for decorators seeking faster, more accurate UV printing workflows.

DPI Laboratory announces the release of Catalyst VisionAI, a camera-based recognition system designed to bring real-time intelligence and positioning control to UV printing workflows. Available now on the Catalyst Aventra and Catalyst Nexus platforms, VisionAI introduces a new approach to alignment, setup, and repeatability in modern UV production.

For years, UV printing has relied on physical jigs to control placement and ensure consistent output. While effective, these fixtures require predefined layouts, manual setup, and fixed spacing that can limit flexibility and slow production. Catalyst VisionAI replaces that dependency with a scanning-based system that allows operators to place items freely on the print bed, initiate a scan, and let the system determine both position and rotational orientation automatically.

“UV printers have become incredibly capable, but they’ve lacked awareness,” Lon Riley, founder of DPI Laboratory, said. “VisionAI allows the system to understand what it’s printing on, not just execute a file. That’s a fundamental shift in how production works.”

From Fixtures to Recognition

Traditionally, achieving precise placement required designing jobs around fixed jig positions. Catalyst VisionAI removes that constraint. By scanning the print bed before execution, the system identifies each item’s location and orientation in real time, enabling accurate placement without manual calibration.

This approach reduces setup time, minimizes operator dependency, and improves consistency across production runs. It also enables tighter spacing of items on the bed, increasing throughput and making more efficient use of available print area.

“A lot of production loss happens before the print even starts,” Riley added. “If placement isn’t consistent, nothing else matters. VisionAI brings structure to that part of the process.”

Built for Production

While camera-based printing demonstrations have gained attention online, many focus on visual impact rather than real-world efficiency. DPI Laboratory emphasizes that VisionAI is designed for practical production environments, particularly high-volume runs where a single image is applied consistently across large quantities of identical items.

In these scenarios, VisionAI enables faster loading, reduced setup time, and lower error rates compared to traditional workflows. At the same time, DPI Laboratory maintains that jig-based workflows remain essential for certain applications, such as multi-design or mixed-item jobs.

“There’s a lot of noise around this technology right now,” Riley said. “Some of it looks impressive, but doesn’t translate to real production. Our focus was building a system that performs day in and day out. There are times where the camera is the right tool, and times where a jig is the better choice.”

Integrated by Design

A key differentiator of Catalyst VisionAI is its full integration into the Catalyst Platform. Unlike retrofit camera systems that rely on multiple software layers or external components, VisionAI is built as part of a unified production architecture, connecting hardware, software, and workflow into a single system.

The technology is supported domestically by DPI Laboratory, with installation, training, and service managed within the United States. The result is a faster, more accurate, and easier-to-use system designed for real production environments.

“We get asked a lot how we’re able to move quickly with VisionAI while larger brands haven’t,” Riley said. “The reality is most legacy platforms were never designed for this type of technology. You can’t bolt intelligence onto a system after the fact. The Catalyst Platform was built with this in mind from the beginning, so this is a natural evolution for us.”

Expanding the Catalyst Platform

Catalyst VisionAI is available immediately on both the Catalyst Aventra and Catalyst Nexus systems, extending intelligent positioning capabilities across both mid-range and high-volume production environments. The technology operates within the broader Catalyst Platform, which integrates UV printing hardware, bulk ink delivery, color management, coatings, and workflow software into a structured production system.

By combining VisionAI with existing jig-based workflows, DPI Laboratory provides operators with multiple production methods within a single platform, allowing them to select the most efficient approach for each job.