Consumable filaments having reversible reinforcement for extrusion-based additive manufacturing

Patent metadata

Field	Value
Publication number	US-10370510-B2
Application number	US-201415028224-A
Country	US
Kind code	B2
Filing date	Oct 2, 2014
Priority date	Oct 8, 2013
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A consumable assembly for use with an additive manufacturing system to print three-dimensional parts, the consumable assembly including a supply device (e.g., a spool) and a filament supported by the supply device, where the filament has a composition comprising one or more elastomers and one or more reinforcing additives, and a filament geometry configured to be received by a liquefier assembly of the additive manufacturing system. The composition is preferably configured to be thermally and/or chemically modified to reduce its flexural modulus.

First claim

The invention claimed is:

1. A method of building a three-dimensional part with an additive manufacturing system, the method comprising:
providing a supply of feedstock material to a liquefier of the additive manufacturing system wherein the feedstock material comprises at least 50% by weight an elastomer and up to 50% by weight a reinforcing additive wherein the feedstock material has a flexural modulus greater than about 300 megaPascals (MPa);
heating the feedstock material in the liquefier and extruding the molten feedstock material through a nozzle provided in an outlet of the liquefier;
depositing the molten feedstock material in a layer by layer manner to build the three-dimensional part; and
chemically treating the three-dimensional part to dissolve or weaken at least a portion of the reinforcing additive such that the flexural modulus of the three-dimensional part is less than the flexural modulus of the feedstock material.

2. The method of claim 1 , wherein chemically treating the three-dimensional part comprises using a water-based solution to dissolve or weaken the reinforcing additive to decrease the flexural modulus of the three-dimensional part.

3. The method of claim 1 , wherein chemically treating the three-dimensional part comprises using an acidic solution to dissolve or weaken the reinforcing additive decrease the flexural modulus of the three-dimensional part.

4. The method of claim 1 , wherein the elastomer is an elastomeric thermoplastic material derived from polyolefins, polyesters, styrenics, polyurethanes, or combinations thereof.

5. The method of claim 1 , wherein the reinforcing additive comprises mineral whiskers, mineral salts, or combinations thereof and wherein the feedstock material of has a flexural modulus greater than about 1500 MPa.

6. The method of claim 5 , wherein after chemically treating the three-dimensional part to dissolve or weaken the reinforcing additive the three-dimensional part has a flexural modulus less than about 1500 MPa.

7. A method of building a three-dimensional part with an additive manufacturing system, the method comprising:
providing a supply of feedstock material to a liquefier of the additive manufacturing system wherein the feedstock material comprises at least 50% by weight an elastomer and up to 50% by weight a reinforcing additive wherein the feedstock material has a flexural modulus greater than about 300 megaPascals (MPa);
heating the feedstock material in the liquefier to a temperature that thermally degrades or softens at least a portion of the reinforcing additive;
extruding the molten feedstock material through a nozzle provided in an outlet of the liquefier; and
depositing the molten feedstock material in a layer by layer manner to build the three-dimensional part, wherein the flexural modulus of the three-dimensional part is less than the flexural modulus of the feed stock material.

8. The method of claim 7 , wherein the reinforcing additive is a polymer fiber comprising polypropylene, polylactic acid, polyamide-6 fibers or combinations thereof.

9. The method of claim 7 , wherein the elastomer is an elastomeric thermoplastic material derived from polyolefins, polyesters, styrenics, polyurethanes, or combinations thereof.

Assignees

• Stratasys Inc

Inventors

• Cernohous Jeffrey Jacob
• Pawloski Adam R
• Demuth Benjamin A

Classifications

• B29K2995/0082

  Flexural strength; Flexion stiffness · CPC title

• B29C48/022

  characterised by the choice of material · CPC title

• C08J2477/06

  Polyamides derived from polyamines and polycarboxylic acids (C08J2477/10 takes precedence) · CPC title

• C08J2467/04

  Polyesters derived from hydroxy carboxylic acids, e.g. lactones (C08J2467/06 takes precedence) · CPC title

• C08J2429/04

  Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids · CPC title