Fusing and Detailing Agents for 3D Printing Color Uniformity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current 3D printing technologies face limitations in commercial production due to restricted material ranges and issues with achieving uniform coloration and surface quality in 3D printed parts, particularly with thermoplastic polymer powders.

Innovation Solution

The use of a fusing agent and detailing agent combination, where the fusing agent includes a carbon black pigment for energy absorption and the detailing agent contains water, black dye, and cyan dye to provide cooling and color uniformity, preventing thermal bleed and enhancing surface appearance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If selective laser sintering is used to melt powder for 3D printing, then complex parts can be manufactured, but the systems become very expensive

Engineering Contradiction:

Improvemanufacturing capabilityVSAvoidsystem cost

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The patent replaces the mechanical laser heating system with a fluid jet printing system that deposits fusing agents containing carbon black pigment. This substitution eliminates the need for expensive laser equipment while achieving the same selective melting effect through chemical absorption of electromagnetic radiation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the heating mechanism from direct laser energy to indirect chemical absorption. The fusing agent containing carbon black pigment absorbs electromagnetic radiation and converts it to thermal energy, fundamentally changing how heat is generated and applied to the thermoplastic powder.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If thermoplastic polymer powder is used for 3D printing, then rapid prototype creation is enabled, but material range for commercial production is limited

Engineering Contradiction:

Improveprototype creation speedVSAvoidmaterial range

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent uses composite material systems consisting of thermoplastic polymer powder combined with fusing agents containing carbon black pigment and detailing agents with dyes. This composite approach enables commercial production with expanded material options while maintaining rapid manufacturing capabilities.

Inventive Principle:

Principle #40Composite materials

3Use of energy by moving object

If carbon black pigment is used as energy absorber in fusing agent, then electromagnetic energy absorption is improved, but coloration uniformity becomes difficult to achieve

Engineering Contradiction:

Improveenergy absorptionVSAvoidcoloration uniformity

Core Design Contradiction:

Use of energy by moving objectVSManufacturing precision

Solution Approach 1:

The patent applies different compositions to different locations: carbon black pigment concentration varies between fusing agent zones and detailing agent zones. This local variation in material composition enables selective energy absorption in fusion areas while maintaining color uniformity in non-fusion areas through controlled detailing agent application.

Inventive Principle:

Principle #3Local quality

4Productivity

If high energy absorption is achieved with carbon black pigment, then fusing efficiency improves, but thermal bleed to surrounding areas increases

Engineering Contradiction:

Improvefusing efficiencyVSAvoidselectivity

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent uses detailing agents as intermediary substances deposited between fusing agent zones. These detailing agents containing dyes act as thermal barriers that absorb excess heat and prevent thermal bleed to surrounding areas, thereby improving selectivity while maintaining high fusing efficiency in the targeted zones.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 fast and accurate 3D printing with improved selectivity between fused and unfused areas, maintaining consistent coloration and surface quality, thereby overcoming material limitations and achieving better commercial production capabilities.

Implementation Method 1

The fusing agent can include an energy absorber to absorb electromagnetic energy to generate sufficient heat to fuse the thermoplastic polymer powder

Methodology Applied

Scientific EffectElectromagnetic energy absorption: Absorption (EM radiation)

Implementation Method 2

The detailing agent can act to cool the powder onto which it may be printed

Methodology Applied

Scientific EffectEvaporative cooling: Evaporative Cooler

Data Source

PatentEP3448941B1Material sets

Publication Date: 2022.06.08 HEWLETT PACKARD DEVELOPMENT COMPANY LP

Figure 1a~1d
Figure 2a~2b
Figure 3

AI summary

The present disclosure is drawn to material sets and 3-dimensional printing systems that include a fusing agent. One example of a material set can include a fusing agent and a detailing agent. The fusing agent can include water, a carbon black pigment, and a water-soluble co-solvent in an amount from 20 wt% to 60 wt%. The detailing agent can include water and a black dye. In another example, a material set can include a fusing agent and a thermoplastic polymer powder.