Multi-structured 3D Printing with Localized Ink Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
3D printing of color objects often faces tradeoffs between desired color and mechanical properties, with color objects having lower densities and mechanical strength compared to black objects due to lower radiation absorptivity of color dyes, leading to color shifting and reduced functionality.
Innovation Solution
A 3D printing process that allows for multi-structured objects with different processing parameters for each structure, enabling high-density internal cores with high mechanical strength and lower-density external shells with vivid colors, using fusing agents with varying ink densities and radiation exposure to achieve desired characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If color dyes are used to produce color 3D objects, then the objects have desired color characteristics, but the radiation absorptivity is lower resulting in reduced density and mechanical strength
Solution Approach 1:
The patent applies different ink densities to different spatial regions of the object. High ink density (high radiation absorptivity) is applied to internal core regions where mechanical strength is needed, while low ink density (low radiation absorptivity) is applied to external surface regions where color characteristics are prioritized. This local differentiation resolves the contradiction by optimizing each region for its primary function.
Solution Approach 2:
The object is segmented into multiple structures with different processing requirements. The internal core structure receives high ink density processing for strength, while external shell structures receive low ink density processing for color. This segmentation allows simultaneous optimization of both mechanical strength and color characteristics in different parts of the same object.
2Strength
If higher ink density is used to improve mechanical strength, then density and strength increase, but color shifting occurs away from the intended color
Solution Approach 1:
Different ink densities are selectively applied to different regions: high ink density to internal regions where strength is critical and color accuracy is less important, low ink density to external regions where color accuracy is paramount. This local quality differentiation eliminates color shifting in visible areas while maintaining strength in internal areas.
3Ease of manufacture
If lower cost additive manufacturing systems are used, then production cost decreases, but the quality and strength of produced objects are lower
Solution Approach 1:
The patent changes the ink density parameter across different regions of the object. By using low ink density (requiring less radiation energy) in external regions and high ink density in internal regions, the process achieves high overall strength while maintaining cost-effectiveness. This parameter variation allows standard equipment to produce high-strength objects without requiring expensive specialized systems.
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 production of 3D color objects with higher densities and improved mechanical strength comparable to black objects, while maintaining intended colors without significant color shifting.
Implementation Method 1
The fusing agent is capable of absorbing radiation and converting the absorbed radiation to thermal energy, which in turn melts or sinters the sinterable material that is in contact with the fusing agent
Implementation Method 2
a radiation source to emit radiation
Data Source
AI summary
In an example implementation, a method of printing a multi-structured three-dimensional (3D) object includes forming a layer of sinterable material. The method includes processing a first portion of the sinterable material using a first set of processing parameters and processing a second portion of the sinterable material using a second set of processing parameters. The processed first and second portions form, respectively, parts of a first and second structure of a multi-structured 3D object.