A composition useful for additive manufacturing safety devices such as helmets is comprised of a melt blend of a polycarbonate and polycaprolactone and in particular a polycarbonate that is a copolymer of polysiloxane and polycarbonate, which may also be accompanied by domains of polysiloxane dispersed within the melt blend. The composition desirably is blended by melting the polycarbonate at higher temperature and then later introducing the polycaprolactone at a lower temperature under shear such as exhibited by a twin screw extruder.
A method of forming a contiguous film includes forming a sandwich of two or more template sheets with polymeric pellets positioned therebetween, and the polymeric pellets comprise a melt blend of an amorphous thermoplastic polymer in an amount of about 5 to about 95 weight percent and a thermoplastic semi-crystalline polymer in an amount of about 5 to about 95 weight percent, based on the total weight of the polymeric pellets. The method includes applying pressure, within a press, to the sandwich such that a continuous film is formed from the polymeric pellets between the two or more template sheets. The method includes separating the contiguous film from the two or more template sheets to yield the contiguous film.
A semicrystalline poly ketone powder useful for additive manufacturing may be made by dissolving a polyketone having differential scanning calorimetry (DSC) monomodal melt peak, at a temperature above 50° C. to below the melt temperature of the polyketone, precipitating the dissolved polyketone by cooling, addition of a nonsolvent or combination thereof. The method may be used to form polyketones having a DSC melt peak with an enthalpy greater than the starting polyketone.
C09D 173/00 - Coating compositions based on macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Coating compositions based on derivatives of such polymers
B29K 61/00 - Use of condensation polymers of aldehydes or ketones, as moulding material
B29K 71/00 - Use of polyethers as moulding material
4.
Amorphous thermoplastic additive manufactured articles and method to make them
A semi-crystalline blended polymer useful for additive manufacturing is comprised of an amorphous thermoplastic polymer and a thermoplastic semi-crystalline polymer, each of the polymers being essentially miscible in the other and being blended at a weight ratio of amorphous polymer/semi-crystalline polymer of greater that 1 to about 20. The semi-crystalline blended polymer displays a DSC melt peak enthalpy of at least about 3 joules/g. The semi-crystalline polymer may be made by blending the aforementioned polymers at the weight ratio and subject to heating between the melt temperature of the semi-crystalline polymer and the glass transition temperature of the amorphous polymer. The semi-crystalline blended polymer may revert to essentially an amorphous polymer when additive manufactured by fusing layers of said polymer powders together.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter. In another instance, A composition is comprised of a semicrystalline polyketone powder having a melt peak and a recrystallization peak, wherein the melt peak and recrystallization peak fail to overlap.
C08G 67/02 - Copolymers of carbon monoxide and aliphatic unsaturated compounds
B29B 9/02 - Making granules by dividing preformed material
B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
C08L 73/00 - Compositions of macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Compositions of derivatives of such polymers
C09D 173/00 - Coating compositions based on macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Coating compositions based on derivatives of such polymers
B29K 61/00 - Use of condensation polymers of aldehydes or ketones, as moulding material
B29K 71/00 - Use of polyethers as moulding material
A composition useful for additive manufacturing is comprised of a thermoplastic elastomer blended with an aliphatic polyketone, wherein the thermoplastic elastomer is a continuous phase having dispersed therein separated domains of polyketone. The composition is useful for additive printing methods employing heating and extrusion of the composition to form extrudates that are printed an article comprised of fused layers of the composition. The composition facilitates the formation of extrusion based elastomeric additive manufactured articles.
C08L 53/00 - Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bondsCompositions of derivatives of such polymers
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29K 19/00 - Use of rubber not provided for in a single one of main groups , as moulding material
B29K 21/00 - Use of unspecified rubbers as moulding material
B29K 25/00 - Use of polymers of vinyl-aromatic compounds as moulding material
B29K 61/00 - Use of condensation polymers of aldehydes or ketones, as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 71/00 - Use of polyethers as moulding material
B29K 105/00 - Condition, form or state of moulded material
B33Y 70/00 - Materials specially adapted for additive manufacturing
B33Y 80/00 - Products made by additive manufacturing
C08L 53/02 - Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bondsCompositions of derivatives of such polymers of vinyl aromatic monomers and conjugated dienes
7.
Additive manufacturing break away support material
An additive manufacturing composition useful as a support material for common build materials (e.g., polyamide or polyester) is comprised of a blend of an elastomer toughened styrenic polymer having discreet domains of polymerized conjugate diene dispersed within a styrenic matrix and a vinyl aromatic-maleic anhydride copolymer. The composition may be used as a support material in additive manufacturing methods such as extrusion methods (e.g., fused filament fabrication). The compositions may be tuned to realize the desired adherence to facilitate the desired support while also allowing for the mechanical removal without breakage of the underlying part or residual adhered support material.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29K 25/00 - Use of polymers of vinyl-aromatic compounds as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
Spherical thermoplastic polymer powders useful for additive manufacturing may be made at high throughputs by a method comprising polymer in a dispersing medium at a temperature above the polymer melting temperature (Tm) under shear for short times (e.g., less than 30 minutes) to form a mixture that is then rapid (faster than ambient cooling) cooled below Tm. The method is particularly useful for thermoplastic polymers having a high melt flow index (MFI) or low capillary viscosity at high shear (˜1000 s−1) within 20 or 30° C. of the polymer's melt temperature. The method may also include a crystallizing temperature below Tm and above the glass transition temperature Tg of the polymer to crystallize amorphous polymers or increase the crystallinity of semi-crystalline polymers.
C08J 3/16 - Powdering or granulating by coagulating dispersions
C08J 3/11 - Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in organic liquids from solid polymers
C09D 167/00 - Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chainCoating compositions based on derivatives of such polymers
Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
C08J 3/14 - Powdering or granulating by precipitation from solutions
10.
Producing semi-crystalline pulverulent polycarbonate and use thereof in additive manufacturing
Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 70/00 - Materials specially adapted for additive manufacturing
C08J 3/09 - Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in organic liquids
C08J 3/11 - Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in organic liquids from solid polymers
A polymeric composition comprised of poly(methylmethacrylate) (PMMA) and polylactic acid (PLA) having a surface charge potential of at least about 50 volts in the absence of any other charge enhancing component may be made by melt blending PMMA and PLA, extruding the melt blend through a die and cooling at a rate through Tg of the PLA of at 10° C./min to 1000° C./second. The polymeric composition may be made by melt blowing into a nonwoven fabric. The nonwoven fabric may be charged to a surface potential of at least about 50 electron volts. Such filters may have greater than 95% efficiency at a pressure drop of less than 2 mm Hg even after being exposed to high temperatures (~70° C.) for an hour or more.
A62B 23/02 - Filters for breathing-protection purposes for respirators
D04H 1/4382 - Stretched reticular film fibresComposite fibresMixed fibresUltrafine fibresFibres for artificial leather
D04H 1/56 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
12.
IMPROVED MELT BLOWN ARTICLES AND METHODS TO FORM THEM
A blended polymer comprising, an amorphous thermoplastic polymer and a thermoplastic semi-crystalline polymer, each of the polymers being essentially miscible in the other and being blended at a weight ratio of amorphous polymer/semi-crystalline polymer of greater that 0.05 to about 20 forms a melt blown nonwoven fabric having essentially no defects with long fiber lengths having uniform diameters. The nonwoven fabrics when used as a filter may have greater than 95% efficiency at a pressure drop of less than 2 mm Hg even after being exposed to high temperatures (˜70° C.) for an hour or more.
D04H 1/56 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
D04H 3/016 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness
D04H 3/16 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
B01D 39/16 - Other self-supporting filtering material of organic material, e.g. synthetic fibres
Polymer powders useful for additive manufacturing may be made by contacting carbon dioxide and a crystallizable polymer having at least one carbonyl, sulfur oxide or sulfone group; permeating the carbon dioxide into the polymer for a crystallizing time sufficient to induce crystallization forming an induced crystalized polymer; removing the carbon dioxide; and forming induced crystalized polymer particles having a D90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 100 micrometers equivalent spherical diameter. The carbon dioxide is desirably supercritical carbon dioxide for at least a portion of the crystallizing time. The polymer powders upon heating during additive manufacturing may result in a polymer having less crystallinity or become amorphous.
C08J 3/00 - Processes of treating or compounding macromolecular substances
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
An end capped condensation polymer may be formed by heating a condensation polymer in the presence of an end capping compound to form cleaved condensation polymer reacting at least a portion of the cleaved condensation polymer with the end capping compound to form the end capped condensation polymer. The end capped condensation polymers may be used to form additive manufactured articles having high solids loading and improved processing due to improved rheological behavior.
An additive manufactured condensation polymer article with improved build or Z direction strength may be formed by physically mixing or depositing thereon a chain extender that extends and chemically bonds the polymer chains within and between layers upon heating and fusing during the additive manufacturing process.
C08F 293/00 - Macromolecular compounds obtained by polymerisation on to a macromolecule having groups capable of inducing the formation of new polymer chains bound exclusively at one or both ends of the starting macromolecule
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29C 64/141 - Processes of additive manufacturing using only solid materials
Copolymers of condensation polymers are formed by a method of cleaving and reacting with a chain extender to form an end capped cleaved condensation polymer that is further reacted with a second compound that may be comprised of a further chain extender and condensation polymer that react with a reactive group still remaining in the chain extender capping the cleaved condensation polymer. The method allows the formation of block copolymers, branched copolymers and star polymers of differing condensation polymers bonded through the residue of a chain extender.
C08F 293/00 - Macromolecular compounds obtained by polymerisation on to a macromolecule having groups capable of inducing the formation of new polymer chains bound exclusively at one or both ends of the starting macromolecule
Compositions useful for making additive manufactured articles are comprised of a styrenic thermoplastic elastomer, the styrenic thermoplastic elastomer being comprised of a block copolymer being comprised of at least two blocks of a vinyl aromatic monomer and at least one block of a conjugated diene monomer, and a solid particulate filler dispersed therein, wherein the filler has a surface area of 0.05 m2/g to 120 m2/g. The compositions may be formed into filaments for use in fused filament fabrication additive manufacturing. The filaments display good printability without drying or storage under dry conditions.
C08L 53/02 - Compositions of block copolymers containing at least one sequence of a polymer obtained by reactions only involving carbon-to-carbon unsaturated bondsCompositions of derivatives of such polymers of vinyl aromatic monomers and conjugated dienes
B33Y 70/00 - Materials specially adapted for additive manufacturing
18.
AMORPHOUS THERMOPLASTIC ADDITIVE MANUFACTURED ARTICLES AND METHOD TO MAKE THEM
A semi-crystalline blended polymer useful for additive manufacturing is comprised of an amorphous thermoplastic polymer and a thermoplastic semi-crystalline polymer, each of the polymers being essentially miscible in the other and being blended at a weight ratio of amorphous polymer/semi-crystalline polymer of greater that 1 to about 20. The semi-crystalline blended polymer displays a DSC melt peak enthalpy of at least about 3 joules/g. The semi-crystalline polymer may be made by blending the aforementioned polymers at the weight ratio and subject to heating between the melt temperature of the semi-crystalline polymer and the glass transition temperature of the amorphous polymer. The semi-crystalline blended polymer may revert to essentially an amorphous polymer when additive manufactured by fusing layers of said polymer powders together.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B29C 71/00 - After-treatment of articles without altering their shapeApparatus therefor
Useful thermoplastic polymer powders are formed by a method comprising: cooling a foam comprised of a thermoplastic foam below the brittleness temperature of the thermoplastic polymer, wherein the foam has an average strut dimension of 10 to 500 micrometers, and comminuting the cooled foam to form a thermoplastic polymer powder. The method allows for the efficient grinding of the thermoplastic polymer having improved morphology and desirable characteristics such as dry flow without flow aids.
C09D 173/00 - Coating compositions based on macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Coating compositions based on derivatives of such polymers
C08J 9/00 - Working-up of macromolecular substances to porous or cellular articles or materialsAfter-treatment thereof
In one instance a semicrystalline polyketone powder useful for additive manufacturing is comprised of a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20° C./min and a D90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter. In another instance, A composition is comprised of a semicrystalline polyketone powder having a melt peak and a recrystallization peak, wherein the melt peak and recrystallization peak fail to overlap.
C09D 173/00 - Coating compositions based on macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Coating compositions based on derivatives of such polymers
B33Y 70/00 - Materials specially adapted for additive manufacturing
A semicrystalline polyketone powder useful for additive manufacturing may be made by dissolving a polyketone having differential scanning calorimetry (DSC) monomodal melt peak, at a temperature above 50° C. to below the melt temperature of the polyketone, precipitating the dissolved polyketone by cooling, addition of a nonsolvent or combination thereof. The method may be used to form polyketones having a DSC melt peak with an enthalpy greater than the starting polyketone.
C09D 173/00 - Coating compositions based on macromolecular compounds obtained by reactions forming a linkage containing oxygen or oxygen and carbon in the main chain, not provided for in groups Coating compositions based on derivatives of such polymers
An additive manufacturing composition useful as a support material for common build materials (e.g., polyamide or polyester) is comprised of a blend of an elastomer toughened styrenic polymer having discreet domains of polymerized conjugate diene dispersed within a styrenic matrix and a vinyl aromatic-maleic anhydride copolymer. The composition may be used as a support material in additive manufacturing methods such as extrusion methods (e.g., fused filament fabrication). The compositions may be tuned to realize the desired adherence to facilitate the desired support while also allowing for the mechanical removal without breakage of the underlying part or residual adhered support material.
B29C 64/118 - Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
B29K 25/00 - Use of polymers of vinyl-aromatic compounds as moulding material
B29K 67/00 - Use of polyesters as moulding material
B29K 77/00 - Use of polyamides, e.g. polyesteramides, as moulding material
23.
Semicrystalline pulverulent polyarylethersulfones and method to make them
A semicrystalline polyarylethersulfone (PAES) useful for additive manufacturing may be made by a method comprising: dissolving an amorphous polyarylethersulfone in a polar aprotic halogenated hydrocarbon solvent at a temperature adequate to effectively form a solution, and subsequently and spontaneously bring about reprecipitation of a semicrystalline polyarylethersulfone from the solution. The semicrystalline polyarylethersulfone may have a crystallinity of at least 30% by weight. The semicrystalline PAES, upon being heated, melting and uniting together in layers during additive manufacturing cools without substantially recrystallizing, allows for deformation-free articles to be formed having low residual stress.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
B33Y 70/00 - Materials specially adapted for additive manufacturing
C08J 3/09 - Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in organic liquids
C08J 3/11 - Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques in organic liquids from solid polymers
Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
C08J 3/14 - Powdering or granulating by precipitation from solutions
B29K 69/00 - Use of polycarbonates as moulding material
25.
Producing semi-crystalline pulverulent polycarbonate and use thereof in additive manufacturing
Ways of preparing a partially crystalline polycarbonate powder are provided that include dissolving an amorphous polycarbonate in a polar aprotic solvent to form a first solution of solubilized polycarbonate at a first temperature. The first solution is then cooled to a second temperature, the second temperature being lower than the first temperature, where a portion of the solubilized polycarbonate precipitates from the first solution to form a second solution including the partially crystalline polycarbonate powder. Certain partially crystalline polycarbonate powders resulting from such methods are particularly useful in additive manufacturing processes, including powder bed fusion processes.
C08J 3/14 - Powdering or granulating by precipitation from solutions
B29C 64/153 - Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
patents
