Feedstocks for additive manufacturing and methods for their preparation and use

Patent metadata

Field	Value
Publication number	US-2016012935-A1
Application number	US-201414329795-A
Country	US
Kind code	A1
Filing date	Jul 11, 2014
Priority date	Jul 11, 2014
Publication date	Jan 14, 2016
Grant date	—

Abstract

A feedstock for additive manufacturing includes a matrix material, and one or more barbed fibers disposed within the matrix material. Each barbed fiber includes a central filament and one or more barbed structures configured to extend outwardly from the central filament after extrusion. Methods of making the feedstock and methods of using the feedstock to form three-dimensional objects are also disclosed.

First claim

What is claimed is:

1 . A feedstock for additive manufacturing, the feedstock comprising:
a matrix material; and one or more barbed fibers disposed within the matrix material, wherein each barbed fiber comprises a central filament and one or more barbed structures configured to extend outwardly from the central filament after extrusion.

2 . The feedstock of claim 1 , wherein the one or more barbed structures are configured to extend outwardly from the central filament after the extrusion and before the matrix material solidifies.

3 . The feedstock of claim 1 , wherein the one or more barbed structures are configured to substantially collapse against the central filament during the extrusion.

4 . The feedstock of claim 1 , wherein the matrix material comprises polycarbonate, acrylonitrile butadiene styrene, polycaprolactone, polyphenylsulfone, polyetherimide, or any combination thereof.

5 . The feedstock of claim 1 , wherein the matrix material comprises a ceramic paste, ceramic slurry, or both.

6 . The feedstock of claim 1 , wherein the matrix material comprises concrete, cement, or both.

7 . The feedstock of claim 1 , further comprising one or more additives.

8 . The feedstock of claim 7 , wherein the one or more additives comprise at least one metal configured to provide one or both of electrical conductivity and thermal conductivity to the matrix material.

9 . The feedstock of claim 7 , wherein the one or more additives comprise a magnetic material configured to impart a magnetic property to the central filament, the barbed structures, or both.

10 . The feedstock of claim 1 , wherein the one or more barbed structures comprise a magnetic material.

11 . The feedstock of claim 10 , wherein each barbed structure is configured to have a magnetic property that is identifiable by an electromagnetic field.

12 . The feedstock of claim 1 , wherein the one or more barbed structures comprise a shape memory material.

13 . The feedstock of claim 12 , wherein the shape memory material is configured to be activated by exposure to heat, to an electromagnetic field, or both, to extend the barbed structures outwardly from the central filament.

14 . A method of fabricating a three-dimensional object, the method comprising:
providing a feedstock comprising a matrix material, and one or more barbed fibers disposed in the matrix material, wherein each barbed fiber comprises a central filament and one or more barbed structures configured to extend outwardly from the central filament after extrusion; extruding the feedstock through a nozzle of an additive manufacturing extruder, wherein the one or more barbed fibers are in a non-extended state during the extruding; and depositing a layer of extruded feedstock onto a surface, wherein the one or more barbed structures extend outwardly from the central filament to an extended state after the extruding.

15 . The method of claim 14 , wherein the extended state of the one or more barbed structures reinforces the matrix material.

16 . The method of claim 14 , further comprising:
allowing the matrix material to solidify.

17 . The method of claim 14 , wherein the one or more barbed structures protrude beyond a surface of the matrix material when in the extended state.

18 . The method of claim 14 , further comprising repeating the extruding step and the depositing step one or more times to form one or more additional layers of the extruded feedstock.

19 . The method of claim 18 , wherein the one or more barbed structures extend from one layer into an adjacent layer when in the extended state

20 . The method of claim 14 , wherein the one or more barbed structures deform from the non-extended state to the extended state in the presence of elastic potential energy, an electromagnetic field, thermal energy, or a combination thereof.

21 . The method of claim 14 , further comprising extruding and depositing at least one additional layer of a second feedstock, the second feedstock comprising a second matrix material.

22 . The method of claim 21 , wherein the second feedstock further comprises one or more second barbed fibers disposed in the second matrix material, wherein each second barbed fiber comprises a second central filament and one or more second barbed structures configured to extend outwardly from the second central filament after extrusion.

23 . The method of claim 22 , wherein the one or more second barbed structures in the second matrix material are configured to interact with the one or more barbed structures in an underlying layer of matrix material.

24 . The method of claim 14 , further comprising extruding and depositing a final layer comprising a third matrix material, wherein any barbed structures protruding from any underlying layers are encapsulated by the final layer.

25 . A three-dimensional object, comprising one or more barbed fibers disposed within a matrix material, wherein each barbed fiber comprises a central filament and one or more barbed structures extending outwardly from the central filament.

Assignees

• Empire Technology Dev Llc

Inventors

• Rothfuss Christopher J

Classifications

• C09K5/14

  Solid materials, e.g. powdery or granular · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title

• H01B1/22 Primary

  the conductive material comprising metals or alloys · CPC title

• B28B1/001

  Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material (selective deposition modelling of metallic powder B22F10/00; rapid manufacturing of 3D objects in general and in particular of plastics B29C64/00) · CPC title