3D Printing Color Parts Pre-Fusing Radiation Energy
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Solution Overview
Problem
3D printing of color parts using near-infrared dye-based fusing agents results in lower mechanical strength and density compared to black parts due to lower radiation absorption, leading to 60% to 80% less mechanical strength in color functional parts.
Innovation Solution
A pre-fusing operation is applied to a 3D object layer with a color image area, involving a shortened radiation exposure to generate heat, followed by a fusing operation with longer radiation exposure to enhance interlayer adhesion and mechanical strength, using a system with a sinterable material distributor, fusing agent distributor, and radiation source to control radiation energy application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If near-infrared dye-based fusing agents are used for 3D printing color parts, then color functionality is achieved, but mechanical strength and density decrease significantly (60% to 80% less than black parts)
Solution Approach 1:
The patent applies a pre-fusing operation before the main fusing process. This preliminary action involves exposing the color image area to radiation energy to generate heat and increase temperature, preparing the sinterable material for subsequent fusing. This preliminary heating compensates for the lower radiation absorption of near-infrared dye-based fusing agents, enabling adequate mechanical strength while maintaining color functionality.
Solution Approach 2:
The patent divides the fusing process into two distinct segments: a pre-fusing operation and a main fusing operation. The pre-fusing segment applies radiation energy to generate heat in the color image area, while the main fusing segment completes the sintering process. This segmentation allows optimization of each stage to address the specific challenge of lower radiation absorption in color parts.
2Adaptability or versatility
If near-infrared dye-based fusing agents are used for 3D printing color parts, then color functionality is achieved, but density decreases compared to black parts
Solution Approach 1:
The pre-fusing operation serves as a preliminary action that heats the sinterable material in the color image area before the main fusing process. This preliminary heating ensures more complete sintering and densification during the subsequent fusing operation, compensating for the lower radiation absorption efficiency of near-infrared dye-based fusing agents and achieving density comparable to black parts.
3Strength
If radiation exposure time is increased to improve mechanical strength, then interlayer adhesion improves, but production time increases
Solution Approach 1:
By performing a pre-fusing operation that pre-heats the material, the subsequent main fusing operation can be completed more quickly and efficiently. The preliminary heating reduces the total radiation exposure time needed to achieve adequate interlayer adhesion and mechanical strength, thereby improving production time and productivity.
Solution Approach 2:
The patent implements periodic action by dividing the fusing process into two distinct phases: pre-fusing and main fusing. This periodic application of radiation energy with different parameters (duration, intensity) allows optimization of each phase to achieve the desired mechanical properties while minimizing total process time.
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 produces 3D color functional parts with higher densities and improved mechanical strength comparable to black parts, addressing the strength and density issues of color parts by optimizing radiation energy application.
Implementation Method 1
The fusing agent is capable of absorbing radiation and converting the absorbed radiation to thermal energy
Implementation Method 2
converting the absorbed radiation to thermal energy, which in turn melts or sinters the sinterable material
Implementation Method 3
successive material layers are joined together by fusing, binding, or solidification through processes including sintering, extrusion, and irradiation
Implementation Method 4
successive material layers are joined together by fusing, binding, or solidification through processes including sintering, extrusion, and irradiation
Implementation Method 5
The pre-fusing operation includes a shortened exposure to radiation of the 3D object layer. Greater absorption of the radiation within the color image area generates additional heat that increases the temperature of the sinterable material within the color image area.
Data Source
AI summary
In an example implementation, a method of three-dimensional (3D) printing includes applying a sinterable material, selectively applying a fusing agent on a portion of the sinterable material, applying a first amount of radiation energy to the portion of the sinterable material, and applying a second amount of radiation energy to the portion of the sinterable material different than the first amount of radiation energy.