Variable Reflectance Patterns in 3D Printing for Embedded Codes
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Solution Overview
Problem
Current additive manufacturing techniques face challenges in precisely generating three-dimensional objects with integrated machine-readable patterns, such as barcodes or QR codes, within the object's structure, which are essential for tracking and identification purposes, due to limitations in controlling the density and distribution of fusing agents during the layer-by-layer solidification process.
Innovation Solution
A method involving a processor-based approach that determines object generation instructions to apply fusing agents at varying densities and contone levels corresponding to the reflectance patterns, allowing for the precise formation of machine-readable codes on the object's surface or interior by modifying the object model data and generating contone maps to achieve the desired reflectance and color schemes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fusing agent is applied uniformly across the build material layer, then the solidification process is simple and efficient, but machine-readable patterns with variable reflectance cannot be formed
Solution Approach 1:
The patent applies local quality by varying the density of fusing agent application across different regions of the build material layer. Specifically, higher densities of fusing agent are applied in regions corresponding to darker areas of the machine-readable pattern, while lower densities are applied in lighter areas. This spatial variation in fusing agent density creates the desired variable reflectance pattern on the solidified object surface, enabling precise pattern formation.
Solution Approach 2:
The patent employs parameter changes by modifying the contone level (density) of fusing agent application as a controllable parameter. The system adjusts the fusing agent density parameter across different spatial locations to correspond with the reflectance requirements of the machine-readable pattern. This parameter variation enables the formation of patterns with different reflectance characteristics without changing the fundamental application process.
2Manufacturing precision
If fusing agent density is varied to create reflectance patterns, then machine-readable codes can be formed, but control precision over agent distribution becomes challenging
Solution Approach 1:
The patent implements feedback by using the object model data as a reference guide to determine the spatial distribution and density of fusing agent application. The system continuously references the desired pattern geometry and reflectance characteristics from the digital model, adjusting the fusing agent application accordingly to achieve accurate pattern formation on the solidified object.
Solution Approach 2:
The patent applies preliminary action by pre-calculating and storing the contone map in the object model data before the actual additive manufacturing process. The reflectance pattern requirements are determined in advance based on the desired machine-readable code, allowing the system to precisely control fusing agent density during manufacturing without real-time measurement adjustments.
3Adaptability or versatility
If varying contone levels of fusing agent are applied, then color and reflectance patterns are achieved, but the process complexity increases
Solution Approach 1:
The patent applies universality by using the fusing agent to serve multiple functions simultaneously: it acts as both the solidification catalyst for the build material and the pattern-forming element that creates machine-readable reflectance variations. This multi-functionality eliminates the need for separate patterning processes or additional materials, achieving pattern design flexibility without proportionally increasing system complexity.
Solution Approach 2:
The patent merges the solidification process with the pattern formation process by integrating the reflectance pattern creation directly into the additive manufacturing workflow. The contone map from the object model data is used to control both the placement and density of fusing agent in a single unified process, combining what could be separate operations into one coordinated manufacturing step.
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 accurate reproduction of patterns like barcodes and QR codes on three-dimensional objects, enhancing tracking and identification capabilities while maintaining the object's intended properties and appearance, by varying the application of fusing agents to achieve the required reflectance and color contrast.
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
the solidification method may include heating the layers of build material to cause melting in selected sub-regions
Implementation Method 3
Additive manufacturing techniques may generate a three-dimensional object through the solidification of a build material
Data Source
AI summary
In an example, a method includes operating, by a processor, on object model data. The object model data describes at least part of an object to be generated in additive manufacturing. The method also includes determining, by a processor, pattern data. The pattern data comprising areas of variable reflectance intended to be formed on a portion of the object. The method includes determining, by a processor, object generation instructions to apply a fusing agent to at least part of a layer of build material corresponding to the portion of the object in a density corresponding to the reflectance of the generated pattern data.