Abstract: Such internal decoration is implemented that an object looks a target color as viewed in any direction, and that the object is colored and has image depiction in any cross-section. A method is provided for producing a three-dimensional object by extruding a build material to form a layer corresponding to each of cross-sections obtained by slicing a target object by a plurality of parallel planes, and depositing such layers in sequence so as to form the three-dimensional object. A white material 15 and one or two or more decoration materials 13 of colors other than white, which solidify wider a predetermined condition after extruded from nozzles, are used as the build material. The decoration materials 13 and the white material 15 are mixed to form the layer.

Abstract: A method builds a workpiece using an additive manufacturing process, wherein the workpiece is built up by consolidating material in a layer-by-layer manner. The method includes receiving an initial geometric model defining surface geometry of the workpiece, determining workpiece slices to be consolidated as layers of the workpiece during the additive manufacturing process from the initial geometric model, determining adjusted positions of the workpiece slices adjusted from initial positions of the workpiece slices as determined from the initial geometric model, the determination of the adjusted positions based upon warping of the workpiece expected to occur during or after the additive manufacturing process, and building the workpiece using the additive manufacturing process, wherein the workpiece slices are formed in the adjusted positions.

Abstract: A 3D printing device (100), comprising a melt extrusion module (102), a printing module (103), and a platform module (104). The melt extrusion module (102) comprises a processing chamber (121) consisting of a feed inlet (124) and a discharge outlet (125), as well as an extrusion means (122) and a heating means (123) disposed at the processing chamber; the melt extrusion module (102) is configured to receive an initial material from the feed inlet (124) of the processing chamber (121), and heat and extrude the initial material to convert the initial material into a molten body, which is extruded out of the discharge outlet (125) of the processing chamber (121). The printing module (103) is communicated with the discharge outlet (125) of the processing chamber (121) and is provided with a nozzle (131); the printing module (103) is configured to receive the molten body extruded from the discharge outlet (125) of the processing chamber (121) and guide the molten body to be extruded out of the nozzle (131).

Abstract: A wood-grained polymer substrate includes a plurality of layers of different colors. The substrate is formed into elongated boards and used in the production of various end products similar to natural wood. Methods for producing the wood-grained polymer substrate are also provided.

Abstract: A method for making a mold is provided. The method includes the following steps a) to d): a) in which a polymer solution is discharged from a liquid droplet discharger onto a stage, where the polymer solution is capable of solating at a temperature lower than a sol-gel transition temperature and gelating at a temperature higher than the sol-gel transition temperature; b) in which the polymer solution discharged onto the stage is maintained at a temperature higher than the sol-gel transition temperature; c) in which the liquid droplet discharger and the stage are relatively moved to form a gel layer on the stage, where the gel layer has a shape corresponding to a locus of the relative movement; and d) in which the polymer solution is discharged from the liquid droplet discharger onto the gel layer to laminate another gel layer thereon and obtain a laminated object.

Abstract: A method of building up a dental object includes steps of (i) determining the three-dimensional shape of the object; (ii) mixing at least a first and a second component to form a hardenable composition; (iii) depositing the hardenable composition through a nozzle; (iv) performing steps (ii) and (iii) in combination with moving the nozzle by computer control based on said data. The invention helps providing an object like a dental restoration at maximized geometric and optical quality.

Abstract: A method of injection molding a building product includes providing an injection mold with a plurality of gates located adjacent a perimeter of the injection mold. The method further includes commingling a first material and a second material into a flow, the second material comprising a color that contrasts with a color of the first material and injecting the commingled flow into the plurality of gates to form a building product. Thereafter, the method includes removing the building product from the injection mold. The second material extends through an interior of the building product and appears as contrasting streaks on an exterior of the building product to form a variegated grain appearance. The method also includes notching a portion of the building product, such that the building product has a substantially linear grain in an exposed portion thereof.

Abstract: Methods, systems, and devices for the manufacture of 3D printed components with structurally integrated metal objects using an additive manufacturing system enhanced with a range of possible secondary embedding processes. One or more layers of a three-dimensional substrate can be created by depositing a substrate, and then one or more 3D printed components can be configured on the substrate with one or more metal objects using additive manufacturing enhanced by one or more secondary embedding processes.

Abstract: An additive manufacturing system operates an actuator to move an extruder with reference to a selected first zig-zag pattern to sparsely fill an interior region of an object by extruding a swath of thermoplastic material that has straight portions connected by angled portions. After a first pass using the first zig-zag pattern is completed, a second zig-zag pattern is used to form a complementary swath that forms rigid structure with the first swath. Use of the two patterns is alternated to sparsely fill the interior region in multiple layers of the object until a predetermined distance from a solid fill structure or surface is detected. Transition patterns are then used to increase the density of the swaths in the interior region in the next successive layers of the object until the layer is reached where a solid fill surface is formed over the swaths formed using the transition patterns.

Abstract: Climbing products containing rails decorated using veil products colored, patterned, painted or in combination with marking methods such as company names and logos and resin formulation designed to withstand exposure to UV radiation with minimal change in appearance which create specific appearances for applications, enhance weathering performance, and facilitate processing efficiency. A combination of a filler free resin and coated veil systems to create a synergistic weather resistance surface with self contained color, pattern, picture, logo or combination of said same for climbing products. A system for producing components. Various methods, system, a ladder rail.

Abstract: A three-dimensional printer uses its extruder and build platform to properly orient the build platform within a working volume. In a multi-point leveling operation, the extruder is moved to the z-axis origin at a number of x-y positions within the plane of the build platform, and the height of the build platform is adjusted to meet the extruder at the origin. If the build platform is a meltable material such as a plastic, then this leveling process must be performed while the extruder is cool. A homing operation may be performed periodically after leveling in order to realign the z-axis positions of the build platform and extruder. A non-meltable contact point may be usefully provided so that homing can be performed while the extruder is hot, such as immediately before a build or between a number of builds.

Abstract: An extruder or other tool head of a three-dimensional printer is instrumented to detect contact force against the extruder, such as by a build platform or an object being fabricated. The tool head may also be instrumented to detect deflection forces and the like acting on the tool that might indicate an operating error. The resulting feedback data can be used in a variety of ways to control operation of the three-dimensional printer during fabrication or diagnostics.

Abstract: The present invention relates to a method to produce a polymeric sheet comprising the steps of providing an acid-based polymer, providing a neutralizing agent, the neutralizing agent being selected from the group consisting of an organic metallic compound, a metallic salt of a fatty acid, and an ionomer, or a mixture thereof, providing a processing oil, mixing said acid-based polymer, said neutralizing agent, said processing oil, to obtain a polymeric composition, and processing said polymeric composition to form a polymeric sheet. The polymeric sheet may be used as a component, or as a substrate, of a surface covering. The polymeric sheet may also be used to form polymeric particles which are component of so-called “homogenous”, or substrate-free, surface covering.

Abstract: The invention relates to a hydraulic binder product [12, 10] which includes a mixture of a hydraulic binder [38, 202], a polyvinyl alcohol [14, 204] and a gelling agent [54] which reacts with the polyvinyl alcohol and a method [8] of producing same.

Abstract: Disclosed is an apparatus for manufacturing synthetic wood having spripes, and the method thereof and the syn-thetic wood of the same. The apparatus includes a main extruder comprising a hopper through which a raw material is injected, a heating cylinder which is disposed at a lower side of the hopper so as to melt the raw material, and an extrusion screw which ex-trudes the melted raw material in the heating cylinder; an uneven wood grain forming part which injects the melted different colors raw material in a transverse direction (or diagonal direction) so as to form an uneven stripe pattern in the transverse direction (or diagonal direction) as well as a length direction of synthetic wood and at an outer surface and an inner portion thereof; and a mold which forms the extruded material introduced through the uneven wood grain forming part into an extruded product of synthetic wood.

Abstract: One or more colorants are infused into thermoplastic materials in a randomized pattern to create a unique visual effect in a plastic preform or container. The visual effect may be similar to that of a drop of dye diffusing in water and forming a ribbon pattern. In some embodiments, a desired infusion effect may be achieved by generating inconsistent loading of a colorant-containing intermediate layer to achieve ribbons or swirls of color throughout the preform or a portion thereof.

Abstract: A co-extrusion process for making decorative moldings having a simulated wood appearance and a given profile includes mixing a base material and color particles to form a mixture, the base material having a rigid polymer and the color particles having a different color from the base material and a higher melt temperature than the base material. The mixture is heated and displaced using a feed screw such that the color particles move helically along the trajectory of the feed screw while avoiding backflow and melting to create corresponding helical vein segments within the base material. The mixture is forced through a tubular channel while controlling heat and shear conditions such that the helical vein segments remain substantially intact.

Abstract: The invention is the provision of an elongated imitation wood product or component which has a plastic core and a plastic coating on at least one surface with the coating, which is of two different colours and which has a randomly swirled pattern, giving a realistic appearance of the wood grain of natural wood to the product. The invention further is in the method and equipment for producing such a realistic imitation wood product or component made of plastic.

Abstract: A method for producing leather pellets, and a method for producing compound granules from leather pellets and a polymer material, for use in molded parts or films. The leather pellets are produced through the following steps: Shavings, crust leather remnants and finished leather waste are obtained as waste products in leather production and finished leather processing; the shavings, crust leather remnants and finished leather waste are milled into ground leather stock comprising leather fibers; the ground stock is pressed into leather pellets; and the leather pellets are dried to a residual moisture content of no more than 30% by weight. The leather pellets can be mixed with a polymer material at a ratio of 10-95% by weight and bonded to one another and shaped forming compound granules. The compound granules can be used to produce molded parts by injection molding or films by calendering.

Abstract: Disclosed herein are a method of manufacturing a wood plastic composite panel, including a panel manufacturing process of extruding and cooling a resin complex, such that wood fiber is uniformly dispersed into a synthetic resin matrix, to manufacture the resin complex into the form of a panel, an embossing process of forming a wood pattern corresponding to the cut-open surface of a natural lumber on the surface of the panel to a predetermined depth, and a brushing process of removing some of a synthetic resin layer from the surface of the panel to form linear micro concavo-convex parts to a predetermined depth, and an apparatus for manufacturing a wood plastic composite panel that is capable of efficiently performing the same.

Abstract: Untreated, embossed surfacing veils with no whitening additives can be used in a fiber-reinforced process to make parts that are more vibrant in color. The lack of whitening agents minimizes the color pollution and provides a part that is richer in color with a smooth, glossy surface. Fabrics with unbonded areas used as surfacing veils allow the veils to be more flexible, improving the performance in the process. High air permeability above 685 cubic feet per minute per square foot is also beneficial in allowing resin to freely flow through the surfacing veil.

Abstract: The artificial marble with good natural pattern and color in accordance with the present invention is prepared mixing ununiformly at least two liquid resins through a line mixer 1, feeding the ununiformly mixed resin on a moving steel belt 4 at a constant speed through a flexible hose 2 and an exit nozzle 3, and reciprocating the exit nozzle perpendicularly to the steel belt by a predetermined program for the exit nozzle to stop at different positions for different durations. The line mixer used in this invention is a Kenics type and has inner elements of eight or less than eight. A line mixer with four to eight elements can be more preferably used.

Abstract: A co-extrusion process for making decorative moldings having a simulated wood appearance and a given profile includes mixing a base material and color particles to form a mixture, the base material having a rigid polymer and the color particles having a different color from the base material and a higher melt temperature than the base material. The mixture is heated and displaced using a feed screw such that the color particles move helically along the trajectory of the feed screw while avoiding backflow and melting to create corresponding helical vein segments within the base material. The mixture is forced through a tubular channel while controlling heat and shear conditions such that the helical vein segments remain substantially intact.

Abstract: A tubular plastic drinking straw having a flat side with a message imprinted on the flat side is formed by an extruding head connected to two extruders, one of which contains an opaque plastic and the other of which extrudes a substantially transparent plastic. The plastics are fed simultaneously through an extruding die which generates a tubular shape with at least one flat side, with the opaque plastic forming a flat side. The flat side is then imprinted with a message formed of characters extending longitudinally along the length of the tube. The tube may then be bent into a sinuous shape for novelty purposes.

Abstract: Inherently colored polyester polymers with controlled branching include a chromophoric co-monomer in their backbone. The chromophoric co-monomer may be a carboxyl terminated chromophoric co-monomer. such as metallo-phthalocyanine tetracarboxylic acid. The inherently colored polyester polymer may be melt-spun into a filament or fiber.

Abstract: A variegated capstock for covering a substrate for a building product has polymeric streaks in a non-clear, non-opaque matrix. Rapid cooling of the matrix minimizes formation of crystallites, such that the polymeric streaks become visible through a surface of the non-opaque matrix. The streaks are visible by having a color or an index of refraction different from that of the matrix. The matrix is in one or more layers, and the polymeric streaks are in the layers. The substrate is visible through the non-clear, non-opaque matrix and can appear partially obscured by the non-clear, non-opaque matrix.

Abstract: Plastic surfacing material of the FOUNTAINHEAD® type having a bold and aesthetically pleasing appearance is achieved by the use TFR pigments, the latter of which are manufactured by orienting reflective flake pigments in a plastic substrate and grinding the substrate to a particulate material.

Abstract: This invention provides methods and devices for manufacturing moldable materials including various types of natural and synthetic clays, edible materials such as cookie dough, and modeling compound by forming a moldable billet through various techniques, and reducing the cross section of said moldable billet such that features in the moldable billet appear in a similar arrangement in the resulting extruded product.

Abstract: Prepare an oriented polymer composition having a decorative appearance by a process including extruding an orientable polymer composition from an extruder, directing the orientable polymer composition through a calibrator and then drawing the orientable polymer composition, optionally through a drawing die, at a drawing temperature to form an oriented polymer composition wherein the process further includes disposing a colorant onto a surface of the oriented polymer composition prior to the calibrator, prior to the drawing die or both prior to a calibrator and prior to the drawing die in a pattern having a width of at least five millimeters and that preferably so that the colorant is at least partially located on a recessed portion of the resulting oriented polymer composition's surface and/or extends to a depth of at least one millimeter below the oriented polymer composition's surface.

Abstract: A process for the production of at least two-colored shaped ceramic parts from a granular ceramic raw material having a first of the at least two colors, wherein the second of the at least two colors is added as a colored pigment or a colored pigment substance and the surface of the granular ceramic raw material is at least partially coated, wherein the coated granular ceramic raw material is then pressed into a solid form.

Abstract: Disclosed herein are a method of manufacturing a wood plastic composite panel, including a panel manufacturing process of extruding and cooling a resin complex, such that wood fiber is uniformly dispersed into a synthetic resin matrix, to manufacture the resin complex into the form of a panel, an embossing process of forming a wood pattern corresponding to the cut-open surface of a natural lumber on the surface of the panel to a predetermined depth, and a brushing process of removing some of a synthetic resin layer from the surface of the panel to form linear micro concavo-convex parts to a predetermined depth, and an apparatus for manufacturing a wood plastic composite panel that is capable of efficiently performing the same.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.

Abstract: The present invention is the apparatus and method for producing a plastic sheet having a pattern produced in a layer therein. The plastic sheet is a single layer sheet or a multi-layer sheet. The pattern is produced by mixing two or more plastic extrudants together in a mixer. The pattern is visible in the layer containing the two or more plastic extrudants because an at least one of the plastic extrudants is at least partially transparent. The mixer used to produce the pattern includes a housing having an end configured to expel the mixture of the two or more extrudants through a plurality of outlets. The mixer further comprises a rotatable shaft and at least one projection coupled to the shaft and rotatable with the shaft, the at least one projection configured to orient the mixture of the two or more extrudants relative to the plurality of outlets in the housing. The mixer further comprising a thrust bearing configured to couple an end of the shaft to the housing.

Abstract: This invention relates to methods and systems for forming composite extrudates including at least a base polymer, a plurality of fibers dispersed in the base polymer, and one or more colorants forming a visible, multi-color pattern, e.g., mimicking the appearance of natural wood.

Abstract: A process for creating color effects in extrudable material, such as plastic. The process includes the steps of providing a first flow of viscous material of a first color and a second flow of viscous material of a second color, the second color being different from the first color. Next, the first and second flows are combined to form a stream of viscous material, where the stream is characterized by a first band of the first color and a second band of the second color, the second band being adjacent to the first band. The stream of viscous material is fed through a static mixer such that, upon exiting the static mixer, the stream is further characterized by a third band of a third color, the third color being different from the first and second colors, the third band being located between the first and second bands.

Abstract: A gypsum wallboard core, and methods and apparatus for making the same are disclosed. Methods of making a gypsum wallboard core include extruding a gypsum slurry containing water, gypsum, slip agents, water-reducing agents, surfactants and, optional additives, through a die and onto a substantially flat, smooth, moving surface. The die has provisions at its outer sides for the introduction of slip agents into the slurry, and provisions at its lateral outer edges for the introduction of a strength-enhancing agent. Once extruded onto the conveyor belt, the slurry is chemically-activated to set and form a hardened board core which then may be easily removed from the conveyor belt and dried.

Abstract: An apparatus and method for molding balloon catheters is disclosed. The balloon may be molded by providing a polymeric tube within a mold having an interior cavity in the shape of the desired balloon. Microwave energy, which may be generated by a gyrotron, may then be directed toward the mold, to heat the polymeric material without heating the mold. Once heated, pressurized fluid may be injected into the tube to blow the polymeric material against the interior cavity whereupon the material can cool to form the balloon or can be further heatset by additional microwave energy and be cooled to form the balloon. In accordance with one embodiment, microwave energy can also be used without a mold to form a medical device. A polymer extrusion apparatus is disclosed utilizing a microwave energy for heating polymer feedstock material within the extruder tip and die unit just prior to formation of the extrudate product.

Abstract: Plastic surfacing material of the FOUNTAINHEAD® type having a bold and aesthetically pleasing appearance is achieved by the use TFR pigments, the latter of which are manufactured by orienting reflective flake pigments in a plastic substrate and grinding the substrate to a particulate material.

Abstract: A method of making an injection molded article having a marbled appearance, including the steps of: mixing at a temperature of at least 100 degrees ° C. polymeric materials having a thermal conductivity in the range of 0.001 to 0.01 cal/cm-sec-° C. wherein the polymeric materials are selected from the group consisting of polyethylene, polystyrene, polyester, and polycarbonate or combinations thereof, and one or more materials selected from the group consisting of ceramics, ceramic composites, metals and metal alloys in a blended relationship to form a viscous phase mixture, the materials in the viscous phase mixture being selected so that when in a solid phase it has a density greater than 4 grams/cc and a thermal conductivity greater than 0.101 cal/cm-sec-° C. to form a feedstock; cooling the blended viscous phase mixture to form the feedstock; and using the feedstock in an injection molding machine having a zero compression screw to form the article.

Abstract: A spatially-resolved spectrometer is used to measure streaking in molded sample plastic parts produced using a molding tool with various mold inserts which produce certain desired topological surface features upon these sample plastic parts. The measurements from one or more of these sample plastic parts are then provided to a computerized device which appropriately filters the data and calculates overall data shape, average peak and valley shift, and a quality number indicative of data slopes. These calculations are then used to determine an optimum set of ingredients and processing conditions to be used for the full-scale plastic part production.

Abstract: A process for preparing a cleansing bar having well-defined platelet striations therein which comprises extruding a cleansing bar composition having platelets therein to form a cleansing bar using an extruder having a perforated barrier across the cross section of the extruder, wherein the perforated barrier is located at a sufficient distance downstream from the spider to allow well-defined platelet striations to be observed in the finished cleansing bar with the human eye. The perforated barrier is located at a distance from the spider equal to at least about 60%, preferably at least about 70%, of the distance from the spider to the extruder cone outlet of the extruder. Generally, a standard extruder cone length from spider to cone outlet is about 483 mm to about 560 mm.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.

Abstract: An apparatus and a process useful for producing patterned gelatin ribbons for forming patterned soft gelatin capsules are disclosed. The apparatus and process use multiple spreader boxes to form a wide variety of possible patterns.

Abstract: This invention relates to an apparatus end method for introducing various additives in solid form into a soap mass for the ultimate manufacture of soap bars. Specifically, the invention is directed to producing soap bars having a multicolored or marbleized appearance and made from a variety of different colored soap materials. Soap pellets having a color are introduced into a soap plodder as is customary. A second or alternate color of soap pellet is separately introduced into the interior of the plodder just before that point where the helical screw of the plodder enters the barrel of the extruder portion of the plodder.

Abstract: A series of three-dimensional burls are formed in a filled-acrylic solid surface material by curing partially mixed steams of acrylic resin casting compositions with defined parameters of viscosity, density and surface tension.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.

Abstract: An extruded wood imitation component and process is described. The component has a solid core containing coloured polymer material formed from a mix of coloured thermoplastic polymer with veins of contrasting coloured polymer throughout the core and on outer surfaces of the component simulating natural wood. In the extrusion process the mixture includes coloured polymer pellets of different colours and sizes which are mixed and melted in an extruder under controlled conditions to provide contrasting streaks of molten polymer throughout a molten extruded core and on outer surfaces of the core of the extrudate which exits the land of the die.

Abstract: Multilayer polymeric shells for spas, bathtubs and shower enclosures having a textured and marbled surface layer. The shells are produced by forming by extrusion a multilayer polymeric sheet having a marbled appearing top layer, passing the sheet between rollers to impart a textured surface to the marbled top layer of the sheet, and thermoforming the sheets into the structural shells for spas, bathtubs and shower enclosures.

Abstract: Multiphase soaps in which the individual phases are highly visible when viewed from above and from the side have high stability. Their use permits various scent experiences to be achieved during the washing operation.

Abstract: The present invention relates to a method of producing a plank product and related components having a controllable and realistic wood-grain appearance, the planks and related components having at least one accent color, the method including the steps of: a) introducing into an extruder a powdered or pelletized base material and accent color pellets, the base material containing less than about 75% by weight wood flour, and having a vicat softening temperature, the accent color pellets (i) having a higher vicat softening temperature than said base material, and (ii) including a styrene polymer having a high vicat softening temperature and a melt flow index of greater than or equal to 1.