Colored Object Additive Manufacturing With Contone Fusing Control
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Solution Overview
Problem
Existing additive manufacturing techniques struggle to produce three-dimensional objects with precise color gradients and structural integrity by effectively controlling the application of fusing agents, often resulting in objects that are either too dark or require post-processing to achieve desired colors.
Innovation Solution
The method involves applying varying amounts of fusing agents, such as carbon black, to build materials like PA12, PA11, and PP, at specific contone levels to achieve intended colors ranging from the build material color to the fusing agent color, ensuring adequate fusion and structural integrity without excessive cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If varying amounts of fusing agent are applied to achieve color gradients, then color precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by varying the contone level (amount) of fusing agent across different regions of the build material. This allows precise control of color gradients while maintaining a single additive manufacturing process, resolving the contradiction between color precision and manufacturing complexity.
Solution Approach 2:
The patent implements local quality by applying different contone levels of fusing agent to different spatial regions of the build material. This enables color gradients and varied mechanical properties at specific locations without requiring different manufacturing processes, thus improving color precision while managing complexity.
2Strength
If higher amounts of fusing agent are applied to ensure adequate fusion, then structural integrity is improved, but color accuracy deteriorates due to excessive darkness
Solution Approach 1:
The patent uses parameter changes by adjusting the contone level of fusing agent to optimize the balance between fusion adequacy and color accuracy. By varying this parameter spatially, the system achieves both sufficient structural integrity and desired color properties without excessive darkness.
Solution Approach 2:
The patent applies partial action by using minimum necessary amounts of fusing agent (lower contone levels) in regions where color accuracy is prioritized, while using higher amounts only where structural integrity is critical. This avoids excessive application of fusing agent that would cause unwanted darkness while maintaining adequate fusion.
3Device complexity
If uniform fusing agent application is used to simplify manufacturing, then device complexity is reduced, but manufacturing precision of color deteriorates
Solution Approach 1:
The patent applies parameter changes through the contone level mechanism, which allows the additive manufacturing system to vary fusing agent amounts digitally without hardware modifications. This maintains low device complexity while achieving high color precision through software-controlled parameter variation.
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
This approach allows for the generation of three-dimensional objects with precise color gradients and improved mechanical properties by controlling fusing agent density, reducing the need for post-processing and minimizing material waste.
Implementation Method 1
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
Implementation Method 2
the solidification method may include heating the layers of build material to cause melting in selected sub-regions
Data Source
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.