Additive Manufacturing Patterns Using Thermal Bleed Fusion

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Solution Overview

Problem

Additive manufacturing techniques face challenges in creating three-dimensional objects with precise control over color and pattern without altering the mechanical properties of the build material, particularly in achieving patterns that match the color of the material while ensuring thermal fusion across layers.

Innovation Solution

The method involves using a fusing agent and a detailing agent in additive manufacturing, where the fusing agent is applied selectively to areas of the build material, and the detailing agent is used to control thermal bleed, allowing areas without fusing agent to fuse by thermal bleed from surrounding areas, thus maintaining the material's color for the patterned areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a fusing agent is selectively applied to create patterns, then visual contrast and pattern definition are improved, but the mechanical properties and color uniformity of the build material deteriorate

Engineering Contradiction:

Improvevisual contrastVSAvoidmechanical properties

Core Design Contradiction:

Illumination intensityVSStrength

Solution Approach 1:

The detailing agent acts as an intermediary substance that modifies thermal energy distribution during the additive manufacturing process. It is applied to regions where patterns should form and controls the thermal bleed from surrounding fusing agent-applied areas, enabling pattern creation without direct fusing agent contact in those regions, thus preserving material color and mechanical properties while achieving visual contrast.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the thermal parameters in specific regions by applying the detailing agent, which modifies how thermal energy is distributed and retained. This allows controlled thermal bleed from surrounding areas to fuse material in pattern regions without the fusing agent, changing the local thermal behavior to achieve both pattern formation and material property preservation.

Inventive Principle:

Principle #35Parameter changes

2Strength

If thermal bleed is used to fuse areas without fusing agent, then material color and mechanical properties are maintained, but manufacturing precision and pattern definition worsen

Engineering Contradiction:

Improvemechanical propertiesVSAvoidpattern definition

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The invention replaces direct mechanical/chemical application of fusing agent in pattern regions with a thermal field-based approach. By using the detailing agent to control thermal bleed from surrounding areas, the system substitutes the direct fusing mechanism with indirect thermal diffusion, allowing pattern formation through energy transfer rather than material application.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention utilizes phase transitions of the detailing agent during the thermal processing cycle. The detailing agent absorbs and releases thermal energy during phase changes, controlling the thermal bleed process to ensure proper fusion of material in pattern regions while maintaining the ability to define precise pattern boundaries through controlled thermal diffusion.

Inventive Principle:

Principle #36Phase transitions

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 enables the creation of objects with patterns that match the color of the build material, ensuring full fusion and maintaining mechanical properties without the need for multi-color printing or additional materials, providing a visual contrast without affecting the object's properties.

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

Methodology Applied

Scientific EffectAbsorption (thermal energy): Absorption (EM radiation)

Implementation Method 2

the solidification method may include heating the layers of build material to cause melting in selected sub-regions

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

allowing areas without fusing agent to fuse by thermal bleed from surrounding areas

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11577463B2Patterns on objects in additive manufacturing

Publication Date: 2023.02.14 PERIDOT PRINT LLC

AI summary

In an example, a method includes operating, by a processor, on object model data and operating, on a processor, on pattern data. The object model data describes at least part of an object to be generated in additive manufacturing and the pattern data describes an object pattern intended to be formed on at least a portion of the part of the object to be generated in additive manufacturing. The method includes determining, by a processor, control data to control a print agent applicator to apply a pattern of fusing agent onto a part of a layer of build material. The pattern of fusing agent comprises a fusing agent area and a gap area that lacks fusing agent. The gap area corresponds to the object pattern such that no fusing agent is applied to a part of the layer of build material that corresponds to the object pattern.