Nested 3D Print Segments for Strong Cores and Bright Shells
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Solution Overview
Problem
Additive manufacturing techniques face challenges in achieving a balance between the mechanical strength and color quality of 3D printed objects, as the absorption of energy for solidification varies with the color of the fusing agent, leading to objects with lower density and strength when colored, and it is difficult to combine high strength with high resilience and bright colors using homogeneous print agents.
Innovation Solution
The method involves segmenting a 3D object model into nested peripheral and core segments, where each segment is processed with specific properties and thickness based on geometry and intended properties, allowing for varying absorption of energy and application of print agents to achieve desired mechanical and visual properties, such as using carbon black for strength and lower-tint agents for colorfulness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If homogeneous print agents are used for the entire object, then the manufacturing process is simple, but the object cannot achieve both high mechanical strength and bright colors simultaneously
Solution Approach 1:
The object is divided into multiple segments (core segment and peripheral segments) that can be processed with different print agents. The core segment uses carbon black-based print agents for high mechanical strength, while peripheral segments use lower-tint print agents for bright colors. This segmentation allows simultaneous optimization of strength and appearance in different regions of the same object.
Solution Approach 2:
Different regions of the object are assigned different print agent properties based on their functional requirements. The core region receives carbon black-based agents for maximum strength, while outer regions receive lower-tint agents for colorfulness. This local differentiation resolves the contradiction by applying appropriate material properties only where needed.
2Strength
If carbon black-based print agents are used to achieve high mechanical strength, then the object gains durability, but the color quality and brightness deteriorate
Solution Approach 1:
The object model is segmented into a core segment and peripheral segments. The core segment is processed with carbon black-based print agents to achieve high mechanical strength and durability, while peripheral segments are processed with lower-tint print agents to achieve bright colors and high illumination intensity. This spatial separation allows both contradictory requirements to be satisfied in different parts of the object.
Solution Approach 2:
The object effectively becomes a composite structure with different material properties in different regions. The core uses carbon black-rich material for strength, while the periphery uses low-tint material for color brightness. This composite approach allows the object to exhibit both high strength and bright colors simultaneously.
3Illumination intensity
If lower-tint print agents are used to achieve bright colors, then the color quality improves, but the mechanical strength and density deteriorate
Solution Approach 1:
The object is divided into peripheral segments and core segment. Peripheral segments use lower-tint print agents for bright colors, while the core segment uses carbon black-based agents for mechanical strength. This ensures that color-critical regions get optimized for appearance while strength-critical regions get optimized for durability.
4Adaptability or versatility
If the entire object is processed with the same processing parameters, then the manufacturing process is efficient, but the object cannot have varying properties in different regions
Solution Approach 1:
The object model is automatically segmented into multiple segments with different processing requirements. Each segment is assigned appropriate print agents and processing parameters based on its intended function. The system processes segments with identical parameters together, maintaining efficiency while enabling property variation across the object.
Solution Approach 2:
The additive manufacturing system is enhanced with multi-functionality to handle different print agent types and processing parameters. The system can automatically select and apply appropriate processing conditions for each segment, providing both versatility in property variation and maintained manufacturing efficiency through automated parameter management.
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 production of objects with balanced mechanical strength and color quality, where colorful shells can be formed around strong cores, and segments can be optimized for specific properties like resilience and appearance, allowing for a gradual transition of properties and enhanced durability.
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
Implementation Method 2
selective solidification of successive layers of a build material... by fusing, binding, or solidification through processes including sintering, extrusion, and irradiation
Data Source
AI summary
In an example, a method includes receiving, at a processor, a data model of an object to be generated in additive manufacturing. A virtual build volume comprising a representation of at least a portion of the object may be segmented into a plurality of nested segments comprising a core segment and a peripheral segment. Segmenting the virtual build volume may comprise determining a dimension of the peripheral segment based on at least one of a geometry of the object and an intended object property.