Coloring Suspensions for Homogeneous Pigment Distribution in Additive Manufacturing

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Solution Overview

Problem

Existing additive manufacturing processes face challenges in homogeneously distributing color pigments in curable binder compositions, particularly due to the rheological properties of the pigments, which can affect the process efficiency and the final product's color consistency.

Innovation Solution

The method involves adding liquid coloring suspensions to the curable binder composition before application, with the suspensions comprising a color pigment and water. These suspensions can be added at the print head or in the supply line, allowing for real-time color changes and the production of multi-colored construction elements within a single printing process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If color pigments are added directly in the extrusion head, then real-time color changes are possible, but homogeneous distribution of pigments is difficult to achieve

Engineering Contradiction:

Improvereal-time color changesVSAvoidhomogeneous pigment distribution

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The patent prepares coloring suspensions in advance with optimized rheological properties (using dispersants and viscosity modifiers) before adding them to the binder composition. This preliminary preparation ensures the suspensions are ready for efficient pumping and homogeneous mixing when introduced into the extrusion system, resolving the contradiction between real-time color changes and homogeneous distribution.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent introduces coloring suspensions as an intermediary medium between the color pigments and the binder composition. These suspensions contain pigments pre-dispersed in a liquid carrier with additives that optimize flow and mixing characteristics. This intermediary form allows easy pumping and homogeneous distribution while maintaining the ability to change colors in real-time.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Illumination intensity

If color pigments are added in high concentrations, then strong coloration is achieved, but rheology and setting behavior are affected

Engineering Contradiction:

Improvecolor intensityVSAvoidrheology and setting behavior

Core Design Contradiction:

Illumination intensityVSStability of the object's composition

Solution Approach 1:

The patent changes the physical and chemical parameters of the coloring medium by formulating suspensions with specific viscosity ranges (0.1-10 Pa·s) and incorporating rheology modifiers. This allows achieving strong coloration while maintaining the binder composition's rheological properties and setting behavior within acceptable ranges for additive manufacturing.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If color pigments are pumped through supply lines, then coloration is possible, but efficient intermixing in short time intervals is difficult

Engineering Contradiction:

Improvepumping capabilityVSAvoidintermixing efficiency

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The patent optimizes the rheological parameters of the coloring suspensions by controlling viscosity (0.1-10 Pa·s) and incorporating flow modifiers. These parameter adjustments enable efficient pumping through supply lines while also facilitating rapid and homogeneous intermixing with the binder composition in the extrusion head, thus improving both ease of operation and productivity.

Inventive Principle:

Principle #35Parameter changes

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 use of liquid coloring suspensions enables efficient and precise coloration of curable binder compositions, ensuring homogeneous pigment distribution and maintaining the rheology and setting behavior of the binder composition. This allows for the production of three-dimensional objects with varying colors without significant adjustments to the printing process or the binder composition.

Implementation Method 1

liquid coloring suspensions for coloring curable binder compositions... comprising a color pigment and water

Methodology Applied

Scientific EffectSuspension: Suspension

Data Source

PatentUS20250128473A1Methods and coloring suspensions for coloring curable binder compositions in additive manufacturing processes

Publication Date: 2025.04.24 SIKA TECH AG

AI summary

A method for producing a three-dimensional object from a curable binder composition with an additive manufacturing process, whereby before application of the curable binder composition, at least one, for example at least two, especially at least three, in particular at least four, coloring suspension(s) includes a color pigment and a solvent, especially water, is added to the curable binder composition to color the curable binder composition.