A system and process for producing a homogenous extrudate powder coating composition having predetermined properties, the system comprising a color library database that is configured to store one or more input formulation data objects capable of use in controlling the inputs and operation of an electronically controlled homogenous extrudate mixer.

A process and associated system for creating color effects using extrudable material, such as plastic and metal for example, are presented. Flows of first and second viscous materials of respective colors are provided and then combined in a predetermined pattern to form a stream of combined viscous material. A dynamic mixer is the then used to apply a predetermined dividing, overturning and combining motion to the stream of combined viscous material to partially mix the first viscous material and the second viscous material, such that upon exiting the dynamic mixer, the first material of the first color and the second material of the second color form a color pattern in the stream of combined viscous material. The dynamic mixer has elements configured for acquiring a specific radial orientation in a range of radial orientations that may be varied during the application of the dividing, overturning and combining motion to the stream of combined viscous material to cause variations in the color pattern in the stream of combined viscous material. Sheets of extruded material may be created using such process and system and used in the manufacturing of many different products including, but not limited to, kayaks, stand-up paddle boards, garden furniture and many others. In some embodiments, the sheets may be characterized by color bands extending diagonally with reference to a longitudinal extent of the sheet.

A system for manufacturing bulked continuous carpet filament that is adapted for providing a polymer melt and dividing the polymer melt into a plurality of streams (e.g., at least six or eight streams) to increase a surface area of the polymer melt. The plurality of streams is then exposed to a pressure that is below approximately 5 millibars. The streams are then recombined into a single polymer stream and formed into bulked continuous carpet filament. In various embodiments, an extruder, such as a multi-screw extruder, is used to divide the polymer melt into the plurality of streams.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 25 millibars, or another predetermined pressure. The streams are recombined into a single polymer stream. Polymer from the polymer stream is then formed into bulked continuous carpet filament.

A method of manufacturing bulked continuous carpet filament that includes providing a polymer melt and separating the polymer melt from the extruder into at least eight streams. The multiple streams are exposed to a chamber pressure within a chamber that is below approximately 5 millibars. The streams are recombined into a single polymer stream and formed into bulked continuous carpet filament.

A system and process for producing a homogenous extrudate powder coating composition having predetermined properties, the system comprising a color library database that is configured to store one or more input formulation data objects capable of use in controlling the inputs and operation of an electronically controlled homogenous extrudate mixer.

A process and system for rapidly fabricating small batches of powder coating compositions having desired colors from one or more solid input filaments. An additive manufacturing filament fabricator feeds one or more single-color solid polymer input filaments into a heated mixer in accordance with an input formulation to be liquefied and mixed to produce a homogenous extrudate mixture. The extrudate mixture is solidified on an extrudate receiving platform and is then comminuted by an extrudate mill into a finished powder coating composition having a desired color.

A process and associated system for creating color effects using extrudable material, such as plastic and metal for example, are presented. Flows of first and second viscous materials of respective colors are provided and then combined in a predetermined pattern to form a stream of combined viscous material. In a first aspect, the flow rate of the first viscous material is caused to vary over time in order to vary an amount of the first viscous material in the stream. In a second aspect, which may be used alone or in combination with the first aspect, the first and second viscous materials have distinct viscosities to reduce an amount of color blending between the first color and the second color in the stream of combined viscous material. A static mixer may then be used to apply a predetermined dividing, overturning and combining motion to the stream of combined viscous material to partially mix the first viscous material and the second viscous material, such that upon exiting the static mixer, the first material of the first color and the second material of the second color form a color pattern in the stream of combined viscous material. Sheets of extrudable material may be created using such process and used in the manufacturing of many different products including for example kayaks and stand-up paddle boards.

A process and associated system for creating color effects in extrudable material, such as plastic and metal for example, are presented. Flows of first and second viscous materials of respective colors are provided and then combined in a predetermined pattern to form a stream of combined viscous material. In a first aspect, the flow rate of the first viscous material is caused to vary over time in order to vary an amount of the first viscous material in the stream. In a second aspect, which may be used alone or in combination with the first aspect, the first and second viscous materials have distinct viscosities to reduce an amount of color blending between the first color and the second color in the stream of combined viscous material. A static mixer may then be used to apply a predetermined dividing, overturning and combining motion to the stream of combined viscous material to partially mix the first viscous material and the second viscous material, such that upon exiting the static mixer, the first material of the first color and the second material of the second color form a color pattern in the stream of combined viscous material. Sheets of extrudable material may be created using such process and used in the manufacturing of many different products including for example kayaks and stand-up paddle boards.

A process and associated system for creating color effects using extrudable material, such as plastic and metal for example, are presented. Flows of first and second viscous materials of respective colors are provided and then combined in a predetermined pattern to form a stream of combined viscous material. A dynamic mixer is the then used to apply a predetermined dividing, overturning and combining motion to the stream of combined viscous material to partially mix the first viscous material and the second viscous material, such that upon exiting the dynamic mixer, the first material of the first color and the second material of the second color form a color pattern in the stream of combined viscous material. The dynamic mixer has elements configured for acquiring a specific radial orientation in a range of radial orientations that may be varied during the application of the dividing, overturning and combining motion to the stream of combined viscous material to cause variations in the color pattern in the stream of combined viscous material. Sheets of extruded material may be created using such process and system and used in the manufacturing of many different products including, but not limited to, kayaks, stand-up paddle boards, garden furniture and many others. In some embodiments, the sheets may be characterized by color bands extending diagonally with reference to a longitudinal extent of the sheet.