3D Printed Color Gradients Using Variable Fusing Agent Contone
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Solution Overview
Problem
Existing additive manufacturing techniques struggle to produce three-dimensional objects with precise color gradients and mechanical integrity by efficiently controlling the application of fusing agents, leading to potential cooling and evaporation issues.
Innovation Solution
By varying the contone levels and densities of fusing agents, such as black ink, applied to build materials like PA12, PA11, and PP, the method ensures adequate fusion while maintaining the original color of the build material, allowing for objects with intended color gradients and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fusing agent is applied to build material to ensure adequate fusion, then mechanical integrity is improved, but color accuracy deteriorates due to cooling and evaporation effects
Solution Approach 1:
The patent applies different contone levels of fusing agent to different regions of the build material. Critical areas requiring high mechanical strength receive higher contone levels (more fusing agent), while non-critical areas receive lower contone levels to preserve color accuracy. This spatial variation in fusing agent application resolves the contradiction by making the system's properties non-uniform according to functional requirements.
Solution Approach 2:
The patent varies the contone level parameter of the fusing agent application to control both fusion quality and color outcome. By adjusting this single parameter across different regions, the system achieves adequate mechanical integrity where needed while maintaining color accuracy where critical, thus resolving the contradiction through parameter optimization.
2Strength
If higher contone levels of fusing agent are used to ensure fusion, then mechanical properties are improved, but color gradients and original material color are lost
Solution Approach 1:
The patent implements spatially varying contone levels where each region's fusing agent concentration is optimized for its specific requirements. This allows the system to maintain color purity in regions where mechanical properties are already sufficient, while applying higher fusing agent concentrations only where additional mechanical reinforcement is needed.
3Reliability
If fusing agent application is increased to prevent cooling effects, then fusion quality is improved, but material evaporation and quality issues worsen
Solution Approach 1:
The patent applies the minimum necessary contone level of fusing agent required to achieve adequate fusion in each region, avoiding excessive application. This partial action approach ensures fusion quality is sufficient without over-applying fusing agent, thereby preventing cooling effects and material evaporation problems that would arise from excessive application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of three-dimensional objects with consistent or gradient colors and mechanical properties by optimizing fusing agent application, reducing cooling effects and enhancing the quality of printed prototypes.
Implementation Method 1
a first fluid comprising a colorant and a second fluid comprising an absorber to absorb electromagnetic radiation are applied on a layer of particulate material
Implementation Method 2
The fusing agent may have a composition which absorbs energy such that, when energy (for example, heat) is applied to the layer, the build material coalesces and solidifies
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
In one example a method of additive manufacturing includes obtaining object model data and colour data. The object model data describes at least portion of an object to be generated in additive manufacturing using a build material having a first colour and a fusing agent having a second colour different from the first colour. The colour data describes an intended colour of at least portion of the object to be manufactured by additive manufacturing. The intended colour is substantially the first colour, the second colour or a colour therebetween. The method includes determining object generation instructions to apply the fusing agent to a first region of a layer of the build material. The first region of the layer corresponds to portion of the object and the instructions are to apply fusing agent at a contone level such that the colour of the portion of the object corresponding to the first region of the layer of build material is substantially the same as the intended colour as described by the colour data.