Poylmeric composition for use as a temporary support material in extrusion based additive manufacturing

a technology of polymeric composition and additive manufacturing, which is applied in the direction of additive manufacturing processes, manufacturing tools, yarns, etc., can solve the problems of poor impact strength and low softening temperature, difficulty in extrusion and printing quality, and less suitable options for desktop 3d printers. , to achieve the effect of simple mechanical means, easy removal and less labor

Inactive Publication Date: 2016-03-10
JF POLYMERS (SUZHOU) CO LTD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0014]This invention provides a polymeric composition which offer an array of properties which make it highly desirable of use as a temporary support material in three-dimensional printing. The support material of this invention can be used to generate support structures that can be easily removed by simple mechanical means. In other words, removal of the temporary support material can be done in a reasonably short amount of time and accordingly takes less labor. It can be utilized advantageously in manufacturing most 3D printed parts and can be used in most conventional FDM/FFF 3D printers. The material

Problems solved by technology

Furthermore, the generation of potentially toxic degradation products during printing makes ABS a less suitable option for desktop 3D printers because such printers generally do not have a heated build envelope and an effective mechanism to eliminate the odor and toxic degradation products.
However, PLA still suffers from a number of drawbacks, including poor impact strength and a low softening temperature.
The low softening temperature leads to difficulties with extrusion and printing quality.
However removing the temporary support structure in such cases can be very challenging because the adhesion between the support structure and the model is often too strong.
In any case, removing the temporary support structure requires extensive labor and can often lead to poor surface appearance and even mechanical damage to the part being made.
However, a significant drawback associated with utilizing of this class of temporary support materials is the difficulty to preserve

Method used

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  • Poylmeric composition for use as a temporary support material in extrusion based additive manufacturing
  • Poylmeric composition for use as a temporary support material in extrusion based additive manufacturing
  • Poylmeric composition for use as a temporary support material in extrusion based additive manufacturing

Examples

Experimental program
Comparison scheme
Effect test

example 1

[0043]A poly(lactic acid) (PLA) (4043D from NatureWorks, LLC) and a thermoplastic polyurethane (TPU) (Estane TPU S375D from Lubrizol) in the mass ratio of PLA:TPU=25:75 were fed into a 20 mm single-screw extruder with a cylindrical die with a diameter of 3 mm to manufacture a filament with a targeted diameter of 1.75 mm. The processing conditions are as follows:

231(compression(metering4Screw(feed zone)zone)zone)(die)(rpm)120° C.190° C.215° C.190° C.30

[0044]The manufactured filament exhibits an average diameter of 1.75 mm with <±0.05 mm in variation. The TPU has a phase-separated morphology, with TPU and PLA forming the continuous matrix and dispersed phase, respectively.

[0045]The produced material was heated and sandwiched between a glass slide and a cover slip for observation by optical microscopy. The micrograph showed that PLA forms spherical particles, with diameters ranging from several microns to 20 microns, evenly dispersed in a continuous matrix of TPU.

example 2

[0046]The manufactured filament as described in Example 1 was loaded onto a dual-extruder desktop FDM / FFF 3D printer (Replicator 2X from MakerBot Industries, LLC). Several models with large overhang portions were used to test the support performance as well as the ease of support removal. The basic printing conditions are as follows:[0047]Modeling material: PolyPlus™ PLA (manufactured by JF Polymers (Suzhou) Co. Ltd.), printed at 195° C.[0048]Support material: printed at 220° C.[0049]Build plate temperature: 60° C.

[0050]The printing speed used was 90 mm / s. For all models tested, the support structure was adequate in supporting the overhang portions, and can be afterwards removed with simple pulling and tearing actions. In most cases the support can be removed by hand or with simple tools such as tweezers. No residue support material is visible on the printed model, meaning that the fracture always occurs at the support-model interface, as designed. In average it takes 1-2 minutes to...

example 3

[0051]The manufactured filament as described in Example 1 was loaded onto a single-extruder desktop FDM / FFF 3D printer (Up! Plus 2nd Generation from Beijing Tier Times Technology Co., Ltd.). In this case the material is used both as the modeling material as well as the support material. It was found that, once a relatively large model infill density (>50%) is used, the support can be removed easily without breaking the model.

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Abstract

The polymeric composition of this invention can be used as a temporary support material in the additive manufacturing of three dimensional articles without compromising the quality of the ultimate product, reducing printing speed, increasing cost, increasing the incidence of printer jamming, or requiring printers of increased complexity. This invention more specifically discloses a polymeric composition which is particularly useful as a temporary support material for utilization in three-dimensional printing, said polymeric composition being comprised of a first polymeric component which is suitable for use as a modeling material and a second polymeric component which is immiscible with the first polymeric component, wherein the polymeric composition has a continuous phase, wherein the continuous phase is comprised of the second polymeric component, and wherein the polymeric composition has a Shore A hardness of at least 80.

Description

[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62 / 047,723, filed on Sep. 9, 2014. The teachings of U.S. Provisional Patent Application Ser. No. 62 / 047,723 are incorporated herein by reference in their entirety.BACKGROUND OF THE INVENTION[0002]By definition, “rapid prototyping” is a group of techniques that can be used to quickly fabricate a scale model of a physical part or assembly using 3-dimensional computer aided design (CAD) data. In rapid prototyping, construction of the part or assembly is usually done in an additive, layer-by-layer fashion. Those techniques that involve fabricating parts or assemblies in an additive or layer-by-layer fashion are termed “additive manufacturing” (AM), as opposed to traditional manufacturing methods which are mostly reductive in nature. Additive manufacturing is commonly referred to by the general public as “3D printing”.[0003]According to ASTM Committee F42 on Additive Manufacturing Technologies, ther...

Claims

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Application Information

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IPC IPC(8): C08L75/04B29C67/00C08J5/00D01F8/14D01F8/16
CPCC08L75/04B29K2995/006D01F8/14D01F8/16B29C67/0055B29C67/0092C08L2207/04C08L2201/06C08J2375/04C08J2467/04D10B2331/041D10B2331/10B33Y10/00B33Y70/00B29K2067/046B29K2075/00C08J5/00D01F6/92D01F6/94B29C64/40B29C64/118B29C64/106
Inventor LUO, XIAOFANPEI, ZHAOKUNYIN, HAIQING
Owner JF POLYMERS (SUZHOU) CO LTD
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