Method for printing three-dimensional parts with crystallization kinetics control

Patent metadata

Field	Value
Publication number	US-2019111615-A1
Application number	US-201816217435-A
Country	US
Kind code	A1
Filing date	Dec 12, 2018
Priority date	Nov 21, 2012
Publication date	Apr 18, 2019
Grant date	—

Abstract

A method for printing a three-dimensional part with an additive manufacturing system, which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi-crystalline polymers. The method also includes melting the part material in the additive manufacturing system, forming at least a portion of a layer of the three-dimensional part from the melted part material in a build environment, and maintaining the build environment at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.

First claim

1 - 20 . (canceled)

21 . A polymeric-based material configured for use, as a feedstock in an extrusion-based additive manufacturing system, the material comprising:
a substantially uniform blend of one or more semi-crystalline polymers and one or more secondary materials that retard crystallization of the one or more semi-crystalline polymers after the blend has been heated to a melting temperature.

22 . The polymeric-based material of claim 21 , wherein the one or more secondary materials comprises one or more non-amorphous polymers to retard crystallization of the one or more semi-crystalline polymers.

23 . The polymeric-based material of claim 21 , wherein the one or more secondary materials comprises one or more second semi-crystalline polymers polymerized from one or more monomers that are isomers of the one or more base monomers of the one or more semi-crystalline polymers.

23 . The polymeric-based material of claim 21 , wherein the one or more secondary materials comprises one or more amorphous polymers that are at least partially miscible with the one or more semi-crystalline polymers.

24 . The polymeric-based material of claim 21 , wherein the one or more secondary materials comprises one or more amorphous polymers that are substantially miscible with the one or more semi-crystalline polymers.

25 . The polymeric-based material of claim 21 , wherein the one or more amorphous polymers constitute from about 50% by weight to about 85% by weight of a combined weight of the one or more semi-crystalline polymers and the one or more amorphous polymers.

26 . The polymeric-based material of claim 21 and further comprising fillers comprising from about 1% to about 45% by weight of the total weight of the polymeric-based material wherein the blend comprises from about 55% to about 99% by weight of the total weight of the polymeric based material.

27 . The polymeric-based material of claim 25 wherein the filler comprises calcium carbonate, magfillernesium carbonate, glass spheres, graphite, carbon black, carbon fiber, glass fiber, talc, wollastonite, mica, alumina, silica, kaolin, silicon carbide, zirconium tungstate, soluble salts, metals, ceramics, and combinations thereof.

28 . The polymeric-based material of claim 21 and further comprising colorants, fillers, plasticizers, impact modifiers, and combinations thereof.

29 . The polymeric-based material of claim 21 , wherein the one or more semi-crystalline polymers comprise one or more semi-crystalline polyamides, and wherein the one or more secondary materials comprise one or more amorphous polyamides.

30 . The polymeric-based material of claim 29 , wherein the one or more semi-crystalline polyamides comprises polycarpolactum (PA6), polyhexamethyleneaidpamide (PA6,6), polyhexamethylenenonamide (PA6,9), polyhexamethylenesebacamide (PA6,10), polyenantholactum (PA7), polyundecanolactum (PA11), polylaurolactam (PA12), and mixtures thereof and wherein the one or more amorphous polyamides comprises hexamethylenediamine, isophthalic acid, terephthalic acid, and adipic acid (PA6i/6T); polyamides of PA12; 3,3-dimethyl-4,4-diaminodicyclohexylmethane, and isophthalic acid (PA12/MACMI); polyamides of PA12; 3,3-dimethyl-4,4-diaminodicyclohexylmethane, and terephthalic acid (PA12/MACMT); (PA12/MACMI/MACMT); PA6i; PA12/MACM36; PANDT/INDT; polyamides of trimethylhexamethylenediamine and terephthalic acid (PA6/3T); polyamides of cycloaliphaticdiamine and dodecanedioic acid; amorphous polyamides of aliphatic diamines and isophthalic acid and/or terephthalic acid and mixtures thereof.

31 . The polymeric-based material of claim 29 , wherein the semi-crystalline polyamide(s) include PA6; PA6,6; and mixtures thereof and wherein the one or more amorphous polyamides comprises PA6/3T, polyamides of cycloaliphaticdiamine and dodecanedioic acid, and mixtures thereof.

32 . The polymeric-based material of claim 29 , wherein at least a portion of the one or more semi-crystalline polyamides comprise one or more graft semi-crystalline polyamides having a polyamide backbone and one or more impact modifiers grafted to the backbone and wherein the one or more amorphous polyamides comprises one or more graft amorphous polyamides having a polyamide backbone and one or more impact modifiers grafted to the backbone.

33 . The polymeric-based material of claim 32 , wherein the one or more grafted impact modifiers comprises from about 5% to about 15% by weight of the one or more graft semi-crystalline polyamides the one or more graft amorphous polyamides.

34 . The polymeric-based material of claim 21 , wherein the one or more semi-crystalline polymers comprise one or more one or more polyaryletherketones, and wherein the one or more secondary materials comprise one or more polyetherimides.

35 . The polymeric-based material of claim 34 , wherein the one or more semi-crystalline polyaryletherketones comprises polyetherketones (PEK), polyetheretherketones (PEEK), polyetherketoneketones (PEKK), polyetheretherketoneketones (PEEKK), polyetherketoneether-ketoneketones (PEKEKK), mixtures thereof, wherein the one or more polyaryletherketones comprises about 50% by weight to about 90% by weight of the blend, wherein the one or more polyetherimides comprises the remainder of the blend.

36 . The polymeric-based material of claim 34 , wherein the one or more semi-crystalline polyaryletherketones comprises polyetheretherketones (PEEK), wherein the PEEK comprises about 50% by weight to about 90% by weight of the blend, wherein the one or more polyetherimides comprises the remainder of the blend.

37 . The polymeric-based material of claim 21 , wherein the one or more semi-crystalline polymers comprises one or more semi-crystalline polybutylene terephthalates (PBT) and/or one or more semi-crystalline polyethylene terephthalates (PET) and wherein the secondary material comprises one or more amorphous polycarbonates wherein the one or more amorphous polycarbonates comprises from about 50% by weight to about 70% by weight of the blend, wherein the one or more semi-crystalline PBTs and/or the one or more PETs comprises the remainder of the blend.

38 . The polymeric-based material of claim 21 , wherein the one or more semi-crystalline polymers comprises one or more semi-crystalline polyethylene terephthalates and the secondary material comprises one or more amorphous polyethylene terephthalates, wherein the one or more amorphous polyethylene terephthalates comprises between about 10% by weight to about 40% by weight of the blend and wherein the one or more semi-crystalline polyethylene terephthalates comprises the remainder of the blend.

39 . The polymeric-based material of claim 38 wherein the one or more amorphous polyethylene terephthalates comprises glycol-modified polyethylene terephthalates.

40 . The polymeric-based material of claim 38 and further comprising an impact modifier within the blend up to about 5% by weight of the blend.

Assignees

• Stratasys Inc

Inventors

• Rodgers Luke M B
• Jaker Vittorio L

Classifications

• B29C64/10

  Processes of additive manufacturing · CPC title

• B29K2105/0067

  Melt · CPC title

• B29K2079/085

  Thermoplastic polyimides, e.g. polyesterimides, PEI, i.e. polyetherimides, or polyamideimides; Derivatives thereof · CPC title

• B29C2071/022

  Annealing · CPC title

• B29K2995/0039

  Amorphous · CPC title