Internal Variable Opacity Patterns in Additive Manufacturing

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Solution Overview

Problem

Additive manufacturing techniques face challenges in generating three-dimensional objects with internal patterns of variable opacity, as existing methods often require separate manufacture and assembly of multiple object portions, which can alter surface shape and mechanical properties.

Innovation Solution

A method involving the use of fusing agents and detailing agents in additive manufacturing, where pattern data is voxelized and integrated into object model data to generate object generation instructions, allowing for the selective application of print agents and energy to create patterns within the object without altering its surface or mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If separate manufacture and assembly of multiple object portions is used to create internal patterns, then patterns of variable opacity can be generated, but the surface shape and mechanical properties of the object are altered

Engineering Contradiction:

Improveinternal pattern opacityVSAvoidsurface shape

Core Design Contradiction:

Manufacturing precisionVSShape

Solution Approach 1:

The patent merges the pattern creation process with the main object manufacturing by applying print agents directly to the build material during additive manufacturing. This integration allows internal patterns of variable opacity to be created within the object itself without requiring separate manufacturing and assembly of multiple portions, thereby preserving the object's surface shape and mechanical properties while achieving the desired internal pattern complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If separate manufacture and assembly of multiple object portions is used to create internal patterns, then patterns of variable opacity can be generated, but the mechanical properties of the object are altered

Engineering Contradiction:

Improveinternal pattern opacityVSAvoidmechanical properties

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent combines the pattern formation process with the object fabrication process by using print agents applied during additive manufacturing. This approach creates internal patterns of variable opacity within the object's bulk material without requiring assembly of separate portions, thereby maintaining the object's mechanical integrity and strength while achieving the desired internal optical properties.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If existing additive manufacturing methods are used without print agents, then manufacturing process is simpler, but internal patterns of variable opacity cannot be created

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidinternal pattern opacity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces print agents as an intermediary substance that enables internal pattern creation during additive manufacturing. These print agents, when applied to the build material and subsequently cured, create regions of variable opacity within the object without fundamentally complicating the manufacturing process. The print agents act as a mediator between the manufacturing process and the desired internal pattern structure, allowing both relative simplicity and pattern precision to be achieved.

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

Enables the efficient and effective incorporation of internal patterns of variable opacity within three-dimensional objects, maintaining the object's surface appearance and mechanical properties, and allowing for the addition of information like identifiers without separate manufacturing of object portions.

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 EffectEnergy absorption: Absorption (EM radiation)

Implementation Method 2

a detailing agent may be used near edge surfaces of an object being printed

Methodology Applied

Scientific EffectSurface modification:

Data Source

PatentUS11733676B2Patterns of variable opacity in additive manufacturing

Publication Date: 2023.08.22 PERIDOT PRINT LLC

AI summary

In an example, a method includes receiving, by at least one processor, object model data, the object model data describing at least part of an object to be generated in additive manufacturing. Pattern data is also received, wherein the pattern data describes a pattern of variable opacity intended to be formed internally to the object. Object generation instructions for generating an intermediate layer of the object comprising the pattern of variable opacity may be determined by at least one processor.