Single-nozzle particle extruder for feeding FDM (fused deposition modeling) filaments from side surface

Abstract

The invention provides a method for producing a 3D article (1) by fused deposition modeling, the method comprising a 3D printing stage of depositing a 3D printable material (201) layer by layer using a fused deposition modeling 3D printer (500) to provide a 3D article (1) comprising layers (322) of a 3D printed material (202); wherein the 3D printer (500) comprises an extruder portion (510), a nozzle portion (520) disposed downstream of the extruder portion (510), a first feeder (530) and a second feeder (540); wherein the nozzle portion (520) comprises a core-shell nozzle (502) comprising (i) a nozzle core (521) disposed downstream of the extruder portion (510) and (ii) a nozzle shell (522) (not disposed downstream of the extruder portion (510)); wherein the first feeder (530) is configured to feed a particulate material (531) comprising a first 3D printable material (1201) to the extruder portion (510), wherein the first 3D printable material (1201) comprises a first material (1211); wherein the second feeder (540) is configured to feed a filament (320) comprising a second 3D printable material (2201) to the nozzle housing (522), wherein the second 3D printable material (2201) comprises a second material (2211) different from the first material (1211); wherein the 3D printing stage comprises: feeding particulate material (531) to an extruder portion (510) and feeding a filament (320) to a nozzle housing (522); generating a core-shell extrudate (321) via the core-shell nozzle (502); a core-shell extrudate (321) is deposited to provide a 3D printed material (202) comprising a core (330) and a shell (340), the 3D printed material at least partially surrounding the core (330), where the core (330) comprises a first material (1211), and where the shell (340) comprises a second material (2211).

Description

Technical Field

[0001] The invention relates to a method for manufacturing a 3D object. The invention also relates to a 3D object obtainable by this method. Furthermore, the invention relates to a lighting device comprising such a 3D object. Furthermore, the invention may also relate to a 3D printer, such as a 3D printer for use in this method. Background Art

[0002] Additive manufacturing printers are known in the art. For example, US2018126636 describes a 3D printer head that ejects multiple molding melts by receiving molding plastic filaments and molding pellets, the 3D printer head comprising: a filament supply unit that supplies molding plastic filaments; a pellet supply unit that supplies molding pellets; a nozzle tube in which a through portion is arranged in a longitudinal direction, molding pellets are supplied from the pellet supply unit, and the molding pellets move; a rotating screw that is arranged in the through portion of the nozzle tube, pushes the molding pellets to one end of the nozzle tube 32 by rotation, and has a filament supply path for supplying molding plastic filaments formed in the longitudinal direction; a heating portion that melts the molding pellets and the molding plastic filaments by heating the nozzle tube to form multiple molding melts; and a nozzle tip that is connected to one end of the nozzle tube and ejects the molding melt. Summary of the invention

[0003] Digital manufacturing will increasingly change the nature of global manufacturing over the next 10-20 years. One aspect of digital manufacturing is 3D printing. Currently, many different technologies have been developed to produce a variety of 3D printed objects using a variety of materials such as ceramics, metals and polymers. 3D printing can also be used to produce molds, which can then be used to replicate the object.

[0004] The most widely used additive manufacturing technology is the Fused Deposition Modeling (FDM) process. Fused Deposition Modeling (FDM) is an additive manufacturing technology that is typically used for molding, prototyping and production applications. FDM is based on the "additive" principle by laying down material layer by layer; a plastic filament or a metal wire is unwound from a coil and the material is supplied to produce the part. It is possible that the (e.g. thermoplastic) filament is melted and extruded before laying down. FDM is a rapid prototyping technology. Other terms for FDM are "fused filament fabrication" (FFF) or "filament 3D printing" (FDP), which are considered equivalent to FDM. Typically, an FDM printer uses a thermoplastic filament, which is heated to the melting point and then extruded layer by layer (or actually one filament after another) to produce a three-dimensional object. FDM printers are relatively fast, low-cost and can be used to print complex 3D objects. Such printers are used to print a variety of shapes using a variety of polymers. The technology has also been further developed in the production of LED lamps and lighting solutions.

[0005] 3D printing can be performed using filaments or using pellets of 3D printable material. However, providing filaments that are highly filled with fillers appears to be challenging. However, using pellets may also provide 3D objects with relatively rough surfaces. This may be undesirable.

[0006] Therefore, one aspect of the present invention is to provide an alternative 3D printing method and / or 3D (printed) object, which preferably further at least partially eliminates one or more of the above-mentioned disadvantages. The purpose of the present invention may be to overcome or improve at least one disadvantage of the prior art, or to provide a useful alternative.

[0007] In a first aspect, the present invention provides a method for producing a 3D printed object by fused deposition modeling. In an embodiment, the method may include a 3D printing stage, which uses a fused deposition modeling 3D printer to deposit 3D printable materials layer by layer to provide a 3D object including a layer of 3D printed material. In particular, the 3D printer may include an extruder portion, a nozzle portion configured downstream of the extruder portion, a first feeder, and a second feeder. In addition, in an embodiment, the nozzle portion may include a core-shell nozzle, and the core-shell nozzle includes (i) a nozzle core configured downstream of the extruder portion and (ii) a nozzle shell (not configured downstream of the extruder portion). In addition, in an embodiment, the first feeder may be configured to deliver a granular material (including a polymer material) including a first 3D printable material to the extruder portion. In particular, the first 3D printable material may include a first material. In addition, in an embodiment, the second feeder may be configured to deliver a filament including a second 3D printable material to the nozzle shell. In particular, the second 3D printable material may include a second material. More particularly, the second material may be different from the first material. In an embodiment, the 3D printing stage may include feeding a granular material to an extruder portion, and feeding a filament to a nozzle shell. In a further embodiment, the 3D printing stage may include generating a core-shell extrudate via a core-shell nozzle, and depositing the core-shell extrudate to provide a 3D printing material comprising a core and a shell, the 3D printing material at least partially surrounding the core. In particular, the core may comprise a first material, and the shell may comprise a second material. Thus, in a particular embodiment, the present invention provides a method for producing a 3D object by fused deposition modeling, the method comprising a 3D printing stage, the 3D printing stage using a fused deposition modeling 3D printer to deposit a 3D printable material layer by layer to provide a 3D object comprising a layer of 3D printing material; wherein the 3D printer comprises an extruder portion, a nozzle portion configured downstream of the extruder portion, a first feeder and a second feeder; wherein the nozzle portion comprises a core-shell nozzle, the core-shell nozzle comprising (i) a nozzle core configured downstream of the extruder portion and (ii) a nozzle shell (not configured downstream of the extruder portion); wherein the first feeder The invention relates to a method for preparing a 3D printing machine having an extruder and a 3D printing device. The method comprises: providing a granular material comprising a first 3D printable material to an extruder portion, wherein the first 3D printable material comprises a first material; wherein the second feeder is configured to provide a filament comprising a second 3D printable material to a nozzle housing, wherein the second 3D printable material comprises a second material different from the first material; wherein the 3D printing stage comprises: providing the granular material to the extruder portion, and providing the filament to the nozzle housing; generating a core-shell extrudate via a core-shell nozzle; depositing the core-shell extrudate to provide a 3D printing material comprising a core and a shell, the 3D printing material at least partially surrounding the core, wherein the core comprises the first material, and wherein the shell comprises the second material.Thus, the method can provide 3D objects using a single nozzle pellet extruder that feeds FDM filament from the side.

[0008] By this method, 3D printed objects can be manufactured at least in part on the basis of 3D printable particles. Such particles can be easier to manufacture and / or handle than filaments. In addition, the method can be used to print materials that are not easy to form into filaments, such as high viscosity polymers and / or (highly) filled materials, which may be relatively brittle. However, the present method can provide a solution for less smooth particle-based extrusions, because the filament can provide a relatively smooth shell around at least a portion of the core of the particle-based starting material. Therefore, by providing, for example, a granular material as a core, and applying a shell with less granular material and / or a relatively low molecular polymer, a 3D object with a relatively smooth surface can be provided. In particular, at the end of the particle extruder space, the filament can be fed laterally close to the nozzle. This can be a very versatile configuration and can increase the 3D printing speed. Therefore, it is helpful to print (highly) filled polymers and / or polymers with relatively high molecular weight. In addition, by this method, a 3D printing material with a core-shell cross-section can be provided. The particles of the 3D printable material are an embodiment of a granular material (including a polymer material).

[0009] As mentioned above, in an embodiment, the present invention provides a method for producing a 3D object by fused deposition modeling. In particular, the method may include a 3D printing stage, which uses a fused deposition modeling 3D printer to deposit 3D printable materials layer by layer to provide a 3D object including a layer of 3D printing materials. In particular, fused deposition modeling can realize the "additive" principle by laying (or depositing) "3D printable materials" in layers. Therefore, in an embodiment, the object produced by this process can be referred to as a 3D object. As described above, the method includes depositing 3D printable materials in the printing stage. Here, the term "3D printable material" refers to the material to be deposited or printed, and the term "3D printing material" refers to the material obtained after deposition. These materials can be substantially the same, because 3D printable materials can particularly refer to materials in a printer head or extruder at high temperature, and 3D printing materials refer to the same material, but at a later stage of deposition. Here, the term "3D printable material" can also be expressed as "printable material". In an embodiment, the printer nozzle can be a core-shell type with two (or more) openings. The term "printer head" may also refer to a plurality of (different) printer heads; thus, the term "printer nozzle" may also refer to a plurality of (different) printer nozzles.

[0010] In an embodiment, the 3D printer may include an extruder portion. In addition, in an embodiment, the 3D printer may include a nozzle portion. The outlet of the nozzle portion may be particularly narrow compared to the width of the extruder portion. That is, in a specific embodiment, the extruder portion may be cylindrical, and in a specific embodiment, the nozzle may have a circular outlet. Therefore, in such an embodiment, the outlet of the nozzle outlet may be smaller than the diameter of the extruder. Therefore, in an embodiment, the 3D printable material may pass through the nozzle in a funnel-like manner so that the 3D printable material may be deposited (printed) layer by layer. Therefore, in an embodiment, the nozzle portion may be configured downstream of the extruder portion (because the 3D printable material in the extruder portion escapes from the printer head via the nozzle portion), particularly downstream of the nozzle core (see also below). Therefore, the extrudate of the nozzle may be a filamentary material, and the starting material may therefore be a granular material (such as a granule) (including a polymer material).

[0011] The terms "upstream" and "downstream" relate to the arrangement of objects or features relative to the propagation direction of the 3D printable material (here in particular within a 3D printer), wherein downstream can be defined as the direction along which the 3D printable material flows, e.g., the 3D printable material can flow from a first feeder to the extruder part, to the nozzle, and then out of the nozzle. Thus, this can in particular be referred to as the downstream direction (or "downstream"). In a similar manner, upstream can be defined as the direction opposite to the flow direction of the 3D printable material. Thus, this can in particular be referred to as the upstream direction (or "upstream"). Thus, the extruder part or feeder can be arranged upstream of the nozzle; and the nozzle can (therefore) be arranged downstream of the feeder or extruder.

[0012] In an embodiment, the 3D printer may include a first feeder. In addition, the 3D printer may include a second feeder. In a further embodiment, the 3D printer may (also) include a third feeder or (even) a fourth feeder. The first feeder or the second feeder may provide the 3D printable material to the 3D printer.

[0013] In an embodiment, the extruder portion may (also) include a barrel. Furthermore, in an embodiment, the extruder portion may further include a screw. Thus, in an embodiment, the extruder portion may include a barrel and a screw. The barrel may provide a volume for accommodating the 3D printable material. Thus, in this way, the 3D printable material may be fed by the first feeder. In an embodiment, the screw may perform the function of extruding or pushing the 3D printable material, thereby (by turning the screw) pushing the 3D printable material toward the nozzle in a downstream direction.

[0014] Furthermore, in an embodiment, the nozzle portion may include a core-shell nozzle, which includes a nozzle core and a nozzle shell. In an embodiment, the nozzle core may be configured downstream of the extruder portion. Furthermore, in an embodiment, the nozzle shell may not be configured downstream of the extruder portion. In other words, particulate material (such as particles) is fed to the extruder portion by a first feeder and escapes via the nozzle core. The filament is fed (directly) by a second feeder in the nozzle shell. Therefore, the nozzle shell is not configured downstream of the extruder portion. The filament can be pressed through the nozzle shell and escape from the nozzle, for example as a shell surrounding the core material.

[0015] In an embodiment, the 3D printable material may include a 3D printable core material and a 3D printable shell material. These materials may be provided as separate materials (such as particles) and may be introduced into the core-shell nozzle of the corresponding core and shell parts. In this way, a core-shell extrudate may be produced to obtain a deposited 3D printing material with a core-shell configuration. Alternatively, these materials may provide a core-shell filament and may be introduced into the nozzle. In this way, a core-shell extrudate may be produced to obtain a deposited 3D printing material with a core-shell configuration. In the present invention, in particular, the filament 3D printable material is delivered to the shell, and the granular 3D printable material is delivered to the core. Therefore, in an embodiment, the first feeder may be configured to deliver a granular material including a first 3D printable material to the extruder portion. In particular, the first 3D printable material may include a first material (see also below). In addition, in an embodiment, the second feeder may be configured to deliver a filament including a second 3D printable material to the nozzle shell. In particular, the second 3D printable material may include a second material (see also below).

[0016] Note that in an embodiment, the first 3D printable material and the second 3D printable material may be different (see also below). In particular, the first 3D printable material and the second 3D printable material both comprise a polymer material, more particularly a thermoplastic polymer material.

[0017] The term "polymer material" may refer to a blend of different polymers in embodiments, but may also refer to a substantially single polymer type with different polymer chain lengths in embodiments. Thus, the term "polymer material" or "polymer" may refer to a single type of polymer, but may also refer to a plurality of different polymers. The term "printable material" may refer to a single type of printable material, but may also refer to a plurality of different printable materials. The term "printing material" may refer to a single type of printing material, but may also refer to a plurality of different printing materials. Thus, the term "3D printable material" may also refer to a combination of two or more materials.

[0018] Thus, in an embodiment, the 3D printing stage may include generating a core-shell extrudate via a core-shell nozzle. The term "extrudate" may be used to define a 3D printable material downstream of a printer head but not yet deposited. The latter may be expressed as "3D printing material". In fact, the extrudate may be considered to include a 3D printable material because the material has not yet been deposited. After depositing the 3D printable material or extrudate, the material may therefore be indicated as a 3D printing material. Basically, the material may be the same material as the thermoplastic material upstream of the printer head, downstream of the printer head, and may be substantially the same (one or more) materials when deposited. Thus, in an embodiment, the 3D printing stage may include depositing a core-shell extrudate to provide a 3D printing material comprising a core and a shell, the shell at least partially surrounding the core. Note that, in particular, the core may include a first material, and the shell may include a second material.

[0019] In an embodiment, the first material may include a first thermoplastic material. In addition, in an embodiment, the second material may include a second thermoplastic material. In some embodiments, the first thermoplastic material and the second thermoplastic material may be the same. However, in other embodiments, the first thermoplastic material may be different from the second thermoplastic material.

[0020] Materials that may be particularly suitable for 3D printable materials may be selected from metals, glass, thermoplastic polymers, silicone, etc. In particular, 3D printable materials include (thermoplastic) polymers selected from the following: ABS (acrylonitrile butadiene styrene), nylon (or polyamide), acetate (or cellulose), PLA (polylactic acid), terephthalate (such as PET polyethylene terephthalate), acrylic (polymethacrylate, organic glass, polymethyl methacrylate, PMMA), polypropylene (or polypropylene (or polypropene)), polycarbonate (PC), polystyrene (PS), PE (such as expanded high impact polyethylene (or polyethylene), low density (LDPE) high density (HDPE)), PVC (polyvinyl chloride) polyvinyl chloride, thermoplastic elastomers such as copolyester elastomers, polyurethane elastomers, polyamide elastomers, polyolefin-based elastomers, styrene-based elastomers, etc. Optionally, the 3D printable material may include a 3D printable material selected from the group consisting of urea-formaldehyde resins, polyester resins, epoxy resins, melamine formaldehyde, thermoplastic elastomers, and the like. Optionally, the 3D printable material may include a 3D printable material selected from the group consisting of polysulfone. Elastomers, in particular thermoplastic elastomers, may be particularly interesting because they are flexible and may help obtain relatively more flexible filaments including thermally conductive materials. Thermoplastic elastomers may include one or more of the following: styrene block copolymers (TPS (TPE-s)), thermoplastic polyolefin elastomers (TPO (TPE-o)), thermoplastic vulcanizates (TPV (TPE-v or TPV)), thermoplastic polyurethanes (TPU (TPU)), plastic copolyesters (TPC (TPE-E)) and thermoplastic polyamides (TPA (TPE-A)).

[0021] Suitable thermoplastic materials (such as those also mentioned in WO2017 / 040893) may include one or more of the following: polyacetals (e.g., polyoxyethylene and polyoxymethylene), poly(C 1-6alkyl) acrylates, polyacrylamides, polyamides (e.g., aliphatic polyamides, polyphthalamides, and polyaramides), polyamides, polyanhydrides, polyarylates, polyarylethers (e.g., polyphenylene oxide), polyarylether sulfides (e.g., polyphenylene sulfide), polyarylether sulfones (e.g., polyphenylene sulfide), polyarylethersulfones (e.g., polyphenylene sulfone), polybenzothiazoles, polybenzoxazoles, polycarbonates (including polycarbonate copolymers such as polycarbonate siloxanes, polycarbonate esters, and polycarbonate ester siloxanes), polyesters (e.g., polycarbonate, polyethylene terephthalate, polynaphthol esters, polybutylene terephthalate, polyacrylates), and polyester copolymers such as polyester ethers), polyetheretherketones, polyetherimides (including copolymers such as polyetherimide-siloxane copolymers), polyetherketoneketones, polyetherketones, polyethersulfones, polyimides (including copolymers such as polyimide-siloxane copolymers), poly(C 1-6 The thermoplastic polymers may include, for example, poly(vinyl alcohol), poly(vinyl ether), poly(vinyl halides), poly(vinyl ketone), poly(vinyl sulfide), poly(vinyl alcohol), poly(vinyl ester), poly(vinyl ether), poly(vinyl halides), poly(vinyl ketone), poly(vinyl sulfide), poly(vinyl sulfide), poly(vinyl alcohol), poly(vinyl ester), poly(vinyl ether), poly(vinyl halides), poly(vinyl ketone), poly(vinyl sulfide), poly(vinylidene fluoride), and the like, or a combination comprising at least one of the foregoing thermoplastic polymers. Examples of polyamides may include, but are not limited to, synthetic linear polyamides such as nylon-6,6; nylon-6,9; nylon-6,10; nylon-6,12; nylon-11; nylon-12 and nylon-4,6, preferably nylon 6 and nylon 6,6, or a combination comprising at least one of the foregoing. Polyurethanes that may be used include aliphatic, alicyclic, aromatic, and polycyclic polyurethanes, including the foregoing. Also useful are poly(C 1-6 Alkyl) acrylate and poly (C 1-6 The polyolefin may include one or more of polyethylene, polypropylene, polybutene, polymethylpentene (and copolymers thereof), polynorbornene (and polymers thereof), poly-1-butene, poly(3-methylbutene), poly(4-methylpentene), and copolymers of ethylene with propylene, 1-butene, 1-hexene, 1-octene, 1-decene, 4-methyl-1-pentene, and 1-octadecene.

[0022] In certain embodiments, the 3D printable material (and 3D printing material) may include one or more of the following: polycarbonate (PC), polyethylene (PE), high-density polyethylene (HDPE), polypropylene (PP), polyoxymethylene (POM), polyethylene naphthalate (PEN), styrene-acrylonitrile resin (SAN), polysulfone (PSU), polyphenylene sulfide (PPS) and semi-crystalline polyethylene terephthalate (PET), acrylonitrile-butadiene-styrene (ABS), polymethyl methacrylate (PMMA), polystyrene (PS) and styrene-acrylic acid copolymer (SMMA).

[0023] Typically, these (polymer) materials have a glass transition temperature T g and / or melting temperature T m The 3D printable material will be heated by the 3D printer to a temperature of at least the glass transition temperature, typically at least the melting temperature, before exiting the nozzle. Thus, in certain embodiments, the 3D printable material comprises a 3D printable material having a glass transition temperature (T g ) and / or melting point (T m ) and the printer head action may include heating the 3D printable material above the glass transition and in embodiments above the melting temperature (particularly when the thermoplastic is a semi-crystalline polymer). In another embodiment, the 3D printable material includes a thermoplastic having a melting point (T m ) of a (thermoplastic) polymer, and the 3D printing stage may include heating the 3D printable material to be deposited to a temperature of at least the melting point. The glass transition temperature is generally different from the melting temperature. Melting is a transition that can occur in crystalline polymers. Melting may occur when the polymer chains break away from their crystal structure and become a disordered liquid. The glass transition may be a transition that occurs in an amorphous polymer; that is, a polymer whose chains are not arranged in an ordered crystal, but are dispersed in any way, even if they are in the solid state. Polymers can be amorphous, essentially having a glass transition temperature instead of a melting temperature, or (semi-)crystalline, generally having a glass transition temperature and a melting temperature, the latter being generally greater than the former. The glass temperature can be determined, for example, by differential scanning calorimetry. The melting point or melting temperature can also be determined by differential scanning calorimetry.

[0024] The term 3D printable material is also further explained below, but may particularly refer to a thermoplastic material, optionally including additives, whose volume percentage is maximum about 60%, particularly maximum about 30 vol.%, such as maximum 20 vol.% (additive relative to the total volume of thermoplastic material and additive).

[0025] Thus, in an embodiment, the printable material may include two phases. The printable material may include a phase of a printable polymer material, in particular a thermoplastic material (see also below), which phase is in particular a substantially continuous phase. In this continuous phase of the thermoplastic material, there may be a polymer additive, such as one or more of the following: an antioxidant, a heat stabilizer, a light stabilizer, an ultraviolet light stabilizer, an ultraviolet light absorbing additive, a near infrared light absorbing additive, an infrared light absorbing additive, a plasticizer, a lubricant, a mold release agent, an antistatic agent, an antifogging agent, an antibacterial agent, a colorant, a laser marking additive, a surface effect additive, a radiation stabilizer, a flame retardant, an anti-drip agent. The additive may have a useful property selected from optical properties, mechanical properties, electrical properties, thermal properties and mechanical properties (see also above).

[0026] The printable material in an embodiment may include particulate material, i.e. particles embedded in a printable polymer material, the particles forming a substantially discontinuous phase. The number of particles in the total mixture may in particular be no greater than 60 vol.%, relative to the total volume of the printable material (including the (anisotropic conductive) particles), in particular in applications for reducing the coefficient of thermal expansion. Therefore, a 3D printable material may in particular refer to a continuous phase of a substantially thermoplastic material, in which other materials, such as particles, may be embedded. Likewise, a 3D printing material may in particular refer to a continuous phase of a substantially thermoplastic material, in which other materials, such as particles, are embedded. The particles may include one or more additives as defined below. Therefore, in an embodiment, a 3D printable material may include a particulate additive.

[0027] In an embodiment, the first material may include a first thermoplastic material, and the second material may include a second thermoplastic material different from the first thermoplastic material. In a particular embodiment, the first material and the second material differ in one or more of molecular weight, viscosity, chemical composition, filler material, and filler material concentration of the thermoplastic material. These aspects are further discussed below.

[0028] As described above, in an embodiment, the first thermoplastic material and the second thermoplastic material may have different molecular weights. In particular, the first thermoplastic material may have a first average molecular weight M n,1 In addition, in an embodiment, the second thermoplastic material may have a second average molecular weight M n,2 Here, molecular weight may in particular refer to the number average molecular weight. In particular, the method may comprise selecting a first average molecular weight M from the range of 10000-100000 g / mol. n,1 , such as 60000-500000 g / mol, in particular 100000-250000 g / mol. More particularly, the method may comprise selecting the second average molecular weight M from the range of 5000-1000000 g / mol n,2, such as 10000-100000 g / mol, especially 25000-50000 g / mol. In particular, M can be selected n,1 and M n,2 , so that 1 <M n,1 / M n,2 ≤10, especially 1 <M n,1 / M n,2 ≤50, more particularly 1 <M n,1 / M n,2 ≤100. In the embodiment, 2≤M n,1 / M n,2 ≤100, such as 5≤M n,1 / M n,2 ≤50. Therefore, in certain embodiments, the first thermoplastic material may have a first average molecular weight M n,1 , and wherein the second thermoplastic material may have a second average molecular weight M n,2 , where the first average molecular weight M n,1 is selected from the range of 60000-500000 g / mol, and wherein the second average molecular weight M n,2 Selected from the range of 10000-100000 g / mol; wherein 1 <M n,1 / M n,2 ≤ 50. Such an embodiment may be particularly applicable when the core has a relatively low content of (particulate) filler material.

[0029] Note that in certain embodiments, M n,1 Can be equal to M n,2 , that is, M n,1 =M n,2 .

[0030] Alternatively, in (other) embodiments, the first average molecular weight M n,1 The second average molecular weight M may be selected from the range of 5000-1000000 g / mol, such as 10000-100000 g / mol, in particular 25000-50000 g / mol. n,2 Can be selected from the range of 10000-1000000 g / mol, such as 60000-500000 g / mol, in particular 100000-250000 g / mol. In particular, in (other) embodiments, 1 <M n,1 / M n,2 ≤10, such as 1 <M n,1 / M n,2 ≤50, especially 1 <M n,1 / M n,2 ≤100. In the embodiment, 2≤M n,1 / M n,2≤100, such as 5≤M n,1 / M n,2 ≤ 50. Such an embodiment may be particularly applicable when the core has a relatively high content of (particulate) filler material.

[0031] In an embodiment, the first thermoplastic material may have a first glass transition temperature T selected from g,1 and the first melting temperature T m,1 The first transition temperature T t,1 Furthermore, in an embodiment, the second thermoplastic material may have a second glass transition temperature T selected from g,2 and the second melting temperature T m,2 The second transition temperature T t,2 The glass transition temperatures of the first thermoplastic polymer and the second thermoplastic polymer may be different. Alternatively or additionally, the melting temperatures of the first thermoplastic polymer and the second thermoplastic polymer may be different.

[0032] In an embodiment, the method comprises controlling the nozzle temperature T n In particular, during at least a portion of the 3D printing phase, T n >T t,1 and T n >T t,2 As described above, at a temperature above the transition temperature, in an embodiment, the viscosity of the first thermoplastic material and the second thermoplastic material may be particularly low and may therefore flow through the nozzle. Thus, in this way, in the case where the nozzle temperature is above the transition temperature being both the first transition temperature and the second transition temperature, both the first thermoplastic material and the second thermoplastic material may be provided (via the nozzle) at a temperature at which they may flow. In particular, T n ≥(T m,1 +10℃) and T n ≥(T m,2 +10°C). More specifically, T n ≥(T m,1 +100℃) and T n ≥(T m,2 +100°C). Thus, in this way, by providing a nozzle temperature that is (significantly) greater than the transition temperature of the first thermoplastic polymer and the second thermoplastic polymer, the fluidity of the first thermoplastic polymer and the second thermoplastic polymer may be improved. Thus, in a particular embodiment, the first thermoplastic material may have a first glass transition temperature T selected from g,1 and the first melting temperature T m,1 The first transition temperature T t,1 , wherein the second thermoplastic material may have a second glass transition temperature T selected from g,2 and the second melting temperature T m,2The second transition temperature T t,2 , wherein the method may include controlling the nozzle temperature T n , wherein during at least a portion of the 3D printing phase, T n >T t,1 and T n >T t,2 Applicable (especially, where T n ≥(T m,1 +10℃) and T n ≥(T m,2 +10°C), more particularly, where T n ≥(T m,1 +100℃) and T n ≥(T m,2 +100℃)).

[0033] Note that in embodiments, the viscosity of the first thermoplastic material and the second thermoplastic material can be different. However, in other embodiments, the viscosity of the first thermoplastic material and the second thermoplastic material can be the same.

[0034] In an embodiment, a first 3D printable material (including a first thermoplastic material) may have a first viscosity PV1, and a second 3D printable material (including a second thermoplastic material) may have a second viscosity PV2. In particular, the first thermoplastic material and the second 3D printable material may be selected such that 1 < PV1 / PV2 ≤ 50, such as 1 < PV1 / PV2 ≤ 500, particularly 1 < PV1 / PV2 ≤ 5000. More particularly, 10 < PV1 / PV2 ≤ 5000, such as 100 < PV1 / PV2 ≤ 5000, particularly 1000 < PV1 / PV2 ≤ 5000. Thus, in a particular embodiment, the first 3D printable material may have a first viscosity PV1, and the second 3D printable material may have a second viscosity PV2 different from the first viscosity PV1, where 1 < PV1 / PV2 ≤ 500. Alternatively, in an embodiment, the first 3D printable material may have a first viscosity PV1, where the second 3D printable material may have a second viscosity PV2 different from the first viscosity PV1, where 1 < PV2 / PV1 ≤ 50, such as 1 < PV2 / PV1 ≤ 500, particularly 1 < PV2 / PV1 ≤ 5000. More particularly, 10 < PV2 / PV1 ≤ 5000, such as 100 < PV2 / PV1 ≤ 5000, particularly 1000 < PV2 / PV1 ≤ 5000. In particular, PV1 may be greater than PV2 and vice versa. Similarly, this may apply to the (corresponding) 3D printing materials. Note that in an embodiment, the 3D printable material may include a particulate filler material. In particular, the core may include a particulate filler material. Thus, in such an embodiment, the viscosity may particularly refer to the viscosity of the 3D printable material, whether the first 3D printable material or the second 3D printable material. A person skilled in the art can clearly determine the viscosity, for example, using a rheometer. The viscosity may be determined, for example, at a temperature at which the 3D printable material (both) can flow through a nozzle, such as at a temperature that is also suitable as a nozzle temperature.

[0035] The first 3D printable material may include a first material, and the second 3D printable material may include a second material, where these materials may be different.

[0036] Assuming that both 3D printable materials include thermoplastic materials, the 3D printable materials may differ in the type of thermoplastic material and / or the molecular weight of the thermoplastic. Thus, the thermoplastic material may be substantially the same type of polymer material, such as both are PE, but only have different molecular weights. Of course, the type of thermoplastic material may also be different, such as PE and PC. Assuming that one of the first 3D printable material and the second 3D printable material includes a filler material and the other does not include a filler material, the 3D printable materials may be different in the presence of the filler material. Assuming that both the first 3D printable material and the second 3D printable material include a filler material, the 3D printable materials may differ in the concentration of the filler material and / or the type of material.

[0037] Thus, in embodiments, the first material and the second material may differ in terms of the type of thermoplastic material, the type of (particulate) filler material, the weight percentage of the filler material(s), the composition of the thermoplastic material, etc.

[0038] In an embodiment, the first material may include a first thermoplastic material, and optionally a first filler material. In particular, the first material may have a first melt volume rate (MVR1). In an embodiment, the second material may include a second thermoplastic material, and optionally a second filler material. In particular, the second material may have a second melt volume rate (MVR2).

[0039] Filler materials can be particularly advantageous in changing certain properties of the first thermoplastic material and / or the second thermoplastic material. For example, the concentration of the first thermoplastic material in the first material can be particularly controlled, i.e., its volume percentage can be changed by using the first filler material. Similarly, in an embodiment, this also applies to the second material including the second filler material and the second thermoplastic material. In particular, the viscosity of the first material or the second material can be changed by using the first filler material or the second filler material, respectively. In an embodiment, other properties of the first material and / or the second material can be controlled, such as surface properties, roughness, light transmission properties, weight, etc.

[0040] Melt volume rate (or "melt volume flow rate") refers to the rate at which a molten resin is extruded through a die of a specified length and diameter under specified conditions of temperature, load, and piston position in an extrusion plastometer cylinder, and is determined as the volume extruded in a specified time. In an embodiment, the first melt volume rate (MVR1) may be selected from 0.01-100 cm 3 / (10min.) range, such as 0.1-10cm 3 / (10min.), especially 0.5-7.5cm 3 / (10 min.). In an embodiment, the second melt volume rate (MVR2) can be selected from the range of 0.1 - 300 cm 3 / (10 min.), such as 1 - 30 cm 3 / (10 min.), particularly 10 - 20 cm 3 / (10 min.). In an embodiment, MVR1 and MVR2 can be selected such that 1 < MVR1 / MVR2 ≤ 0.0003, such as 1 < MVR1 / MVR2 ≤ 0.003, particularly 1 < MVR1 / MVR2 ≤ 0.03. (According to ISO 1133 12, at 300 °C and 1.2 kg). The international unit of melt volume rate is decimeter per minute (dm 3 / min). The ISO standard defines the melt volume rate in units of cubic centimeters per 10 minutes (cm 3 / 10 min). ISO 1133 12 (which defines the dimensions, temperature, and weight) can be used, for example, to measure the amount of material flowing out per unit time (cm 3 / 10 min). The temperature and weight used during the measurement are 300 °C and 1.2 kg, respectively. Thus, in a particular embodiment, the first material can optionally include a first filler material, where the first material can have a first melt volume rate (MVR1); where the second material can optionally include a second filler material, where the second material (1211) has a second melt volume rate (MVR2), where the first melt volume rate (MVR1) is selected from the range of 0.1 - 1 cm 3 / (10 min.), where the second melt volume rate (MVR2) is selected from the range of 1 - 30 cm 3 / (10 min.); where 1 < MVR1 / MVR2 ≤ 0.003 (according to ISO 1133 12, at 300 °C and 1.2 kg). However, in other embodiments, 1 < MVR2 / MVR1 ≤ 0.0003, such as 1 < MVR20 / MVR1 ≤ 0.003, particularly 1 < MVR1 / MVR1 ≤ 0.03. However, particularly, the more viscous 3D printable material can be sent to the nozzle via the extruder section.

[0041] As previously described, the volume percentage (i.e., the volume fraction of the first material (or second material) included in the first thermoplastic material (or second thermoplastic material)) can be controlled. In an embodiment, the first material may include a (particulate) first filler material at a first volume percentage V1 relative to the first material. The (particulate) first filler material may be embedded in the first thermoplastic material. In addition, in an embodiment, the second material may optionally include a (particulate) second filler material at a second volume percentage V2 relative to the second material. The (particulate) second filler material may be embedded in the second thermoplastic material. Therefore, in an embodiment, V1 may be 0 vol.%. In other embodiments, V2 may be 0 vol.%. However, in other embodiments, V1>V2, wherein V2 may be 0 vol.% or greater. However, in other embodiments, V2>V1, wherein V1 may be 0 vol.% or greater.

[0042] In particular, in an embodiment, the first volume percentage V1 may be selected from the range of 0-90 vol.%, such as 5-50 vol.%, in particular 10-25 vol.%. Note that in an embodiment where the first filler material may not be used, the volume percentage of the first filler material may be 0 vol.%, i.e., the core may be completely filled with the first thermoplastic material. Similarly, in an embodiment, the second volume percentage V2 may be selected from the range of 0-30 vol.%, such as 0-15 vol.%, in particular 0-10 vol.%. More particularly, the second volume percentage V2 may be selected from the range of 5-30 vol.%, such as 10-30 vol.%, in particular 15-30 vol.%. (Also) Note that in an embodiment where the second filler material may not be used, the volume percentage of the second filler material may be 0 vol.%, i.e., the shell may be completely filled with the second thermoplastic material. In an embodiment, V1 and V2 may be selected such that 0≤V2 / V1≤100, in particular 0≤V2 / V1≤10, more particularly 0≤V2 / V1≤1. More particularly, in an embodiment, V1 and V2 may be selected such that 0≤V2 / V1<1, in particular 0≤V2 / V1≤0.5, such as 0≤V2 / V1≤0.05, such as 0≤V2 / V1≤0.01. Thus, in an embodiment, in this way, the core may particularly include more filler material than the shell. For example, the core may include more particulate filler material than the shell. In a specific embodiment, the first material may include a first filler material having a first volume percentage V1 relative to the first material, and wherein the second material may optionally include a second filler material having a second volume percentage V2 relative to the second material, wherein the first volume percentage V1 is selected from the range of 5-50 vol.%, wherein the second volume percentage V2 is selected from the range of 0-15 vol.%, and wherein 0≤V2 / V1≤0.5. However, in other embodiments, the core may also be free of particulate material.

[0043] In addition, in an embodiment, the first material may include a first filler material with a first volume percentage V1 relative to the first material. Similarly, in an embodiment, the second material may include a second filler material with a second volume percentage V2 relative to the second material. In an embodiment, the first filler material and the second filler material (as described above) may be optional. In addition, in an embodiment, the first filler material and the second filler material may be different filler materials in particular. Therefore, in a specific embodiment, the first material may include a first filler material with a first volume percentage V1 relative to the first material, and wherein the second material may include a second filler material with a second volume percentage V2 relative to the second material, wherein the first filler material and the second filler material may be different filler materials. However, in an embodiment, they may (also) be the same material. In a specific embodiment, when the filler material is the same material, the volume percentage may be different. As described above, the filler material may also be different, and the corresponding volume percentages may be different (or optionally the same).

[0044] In particular, in an embodiment, the first filler material is a granular material.Alternatively or additionally, in an embodiment, the second filler material is a granular material.

[0045] In an embodiment, the control system may be configured to control 3D printing conditions. In an embodiment, the control system may control a fused deposition modeling 3D printer (see also below). In an embodiment, a first volume flow rate of a granular material (to an extruder portion) may be controlled. Furthermore, in an embodiment, a second volume flow rate of a filament (to a nozzle housing) may be controlled. Furthermore, in an embodiment, a nozzle temperature T may be controlled. n (as described above). The viscosity of the first material and the second material may be particularly dependent on temperature. Therefore, at higher temperatures and lower viscosities, the flow rates of the first material and / or the second material may be controlled, thereby controlling the first volume flow rate and the second volume flow rate. Therefore, in a particular embodiment, the control system may be configured to control 3D printing conditions; wherein the 3D printing conditions may be selected from: a first volume flow rate of the granular material (to the extruder part), (ii) a second volume flow rate of the filament (to the nozzle housing), and (iii) a nozzle temperature T as described above. n .

[0046] In an embodiment, the method may further include monitoring parameters related to the particle size (d1) of the granular material (i.e., the first 3D printable material). In particular, the particle size (d1) may be related to the size of the granular material, such as length, width, height or diameter. More particularly, other parameters such as weight, density, polydispersity of granular material properties (such as distribution of particle size, shape, density, etc.) may be controlled. In addition, in an embodiment, the method may include controlling the 3D printing conditions according to parameters related to the particle size (d1) (of the particles or tray of the 3D printable material). In particular, the energy input to the extruder portion may be controlled. In addition, in an embodiment, the parameters related to the particle size (d1) may be selected from: (a) particle size (d1), and (b) energy input to the extruder portion. Thus, in certain embodiments, the method may further include: monitoring a parameter related to the particle size (d1) of the particulate material, and controlling the 3D printing conditions based on the parameter related to the particle size (d1); and wherein the parameter related to the particle size (d1) is selected from: (a) the particle size (d1), and (b) the energy input to the extruder portion. Thus, in this way, in embodiments, the material output (weight per time constant) from the printer nozzle may be constant.

[0047] In particular, the 3D printed object may include one or more layers of 3D printed material. More particularly, the 3D printed object includes multiple layers of 3D printed material. The 3D printed object may include two or more layers, such as at least 5 layers, such as at least 10 layers, such as at least 20 layers of 3D printed material in an embodiment. Therefore, in particular, the layer portion may be provided according to the method for producing a 3D printed object described herein.

[0048] The 3D printed object may include multiple layers stacked on top of each other, i.e., stacked layers. For example, in an embodiment, the width (thickness) and height of a layer (of an individual 3D print) may be selected from the range of 100-5000 μm, such as 200-2500 μm, the height being typically smaller than the width. For example, the ratio of height to width may be equal to or less than 0.8, such as equal to or less than 0.6.

[0049] Layers can be core-shell or can consist of a single material. Within a layer, the composition can also change, for example when applying a core-shell printing process, changing from printing the first material (without printing the second material) to printing the second material (without printing the first material) during the printing process.

[0050] The method described herein provides a 3D printed object. Therefore, the present invention also provides, in another aspect, a 3D printed object obtainable by the method described herein. At least a portion of the 3D printed object may include a coating.

[0051] When discussing the method, some specific embodiments related to 3D printing objects have been explained above. Below, some specific embodiments related to 3D printing objects will be discussed in more detail.

[0052] In another aspect, a 3D printed object is provided which can be obtained by the method described herein. In particular, the present invention provides a 3D object which can include 3D printed material. In particular, the 3D object can include layers of 3D printed material. The 3D printing stage as described above can provide a 3D object by depositing 3D printable material layer by layer.

[0053] Layers of printable material may be deposited, from which a 3D printed object may be generated (in a printing phase). However, after the printing phase, another phase may also be performed, such as a finalization phase. This phase may include removing the printed object from the receiver object and / or one or more post-processing actions. One or more post-processing actions may be performed before removing the printed object from the receiver object, and / or one or more post-processing actions may be performed after removing the printed object from the receiver object. Post-processing may include, for example, one or more of polishing, coating, adding functional components, etc. Post-processing may include smoothing the ribbed structure, which may result in a substantially smooth surface.

[0054] In an embodiment, the layer may comprise a core-shell cross-section, comprising a core and a shell. In particular, the shell may at least partially surround the core. In an embodiment, in this way (as described in the 3D printing stage), a highly filled material may be provided in the core, for example, the core may be filled with a (particulate) filler material (embedded in a thermoplastic material).

[0055] In addition, in an embodiment, the core may include a first material. In particular, the shell may include a second material. In an embodiment, as previously described, the core and the shell may particularly include the same material, i.e., the first material may be the same as the second material. However, in other embodiments, the core and the shell may include different materials, i.e., the first material may be different from the second material. Note that in an embodiment, the core may have a first perimeter (p1), the first perimeter having a first deviation (R1), thereby defining a first root mean square roughness RMS1. In addition, in an embodiment, the shell may have a second perimeter (p2), the second perimeter having a second deviation (R2), thereby defining a second root mean square roughness RMS2. In particular, it may be desirable to provide a 3D object with a specific surface roughness. Therefore, in an embodiment, a shell comprising a second material may be particularly selected so that it has a relatively low surface roughness compared to a core comprising a first material. Therefore, in an embodiment, RMS1 and RMS2 may be selected so that RMS1 / RMS2≤5, such as RMS1 / RMS2≤0.5, in particular RMS1 / RMS2≤0.05. Thus, in a particular embodiment, the present invention may provide a 3D object comprising a 3D printed material, wherein the 3D object comprises a layer of the 3D printed material, wherein the layer comprises a core-shell cross-section, comprising a core and a shell, the shell at least partially surrounding the core, wherein the core comprises a first material, and wherein the shell comprises a second material different from the first material, wherein the core has a first perimeter (p1), the first perimeter has a first deviation (R1), thereby defining a first root mean square roughness RMS1, wherein the shell has a second perimeter (p2), the second perimeter has a second deviation (R2), thereby defining a second root mean square roughness RMS2, wherein RMS1 / RMS2≤0.5. In an embodiment, the first root mean square roughness RMS1 may be selected from the range of about 5-25 μm.

[0056] In an embodiment, the first material may include a first thermoplastic material. Additionally, in an embodiment, the second material may include a second thermoplastic material different from the first thermoplastic material.

[0057] In other embodiments, the first thermoplastic material and the second thermoplastic material may be specifically identical. This may provide the benefit of increasing adhesion between the core and the shell. Likewise, this may apply when the first thermoplastic material and the second material are substantially identical chemically but differ only in molecular weight, such as HDPE and LDPE.

[0058] As previously mentioned, the first material and the second material may differ in one or more of molecular weight of the thermoplastic material, viscosity, chemical composition (particularly of the thermoplastic material), filler material, and concentration of filler material.

[0059] As mentioned above, in an embodiment, the first thermoplastic material and the second thermoplastic material may have different molecular weights. In particular, the first thermoplastic material may have a first average molecular weight M n,1 In addition, in an embodiment, the second thermoplastic material may have a second average molecular weight M n,2 In particular, the first average molecular weight M n,1 The second average molecular weight M may be selected from the range of 10000-1000000 g / mol, such as 60000-500000 g / mol, in particular 100000-250000 g / mol. More particularly, the second average molecular weight M n,2 M may be selected from the range of 5000-1000000 g / mol, such as 10000-100000 g / mol, in particular 25000-50000 g / mol. n,1 and M n,2 can be chosen so that 1 <M n,1 / M n,2 ≤10, especially 1 <M n,1 / M n,2 ≤50, more particularly 1 <M n,1 / M n,2 ≤100. Note that in certain embodiments, M n,1 Can be equal to M n,2 , that is, M n,1 =M n,2 Thus, in certain embodiments, the first thermoplastic material may have a first average molecular weight M n,1 , and wherein the second thermoplastic material may have a second average molecular weight M n,2 , where the first average molecular weight M n,1 is selected from the range of 60000-500000 g / mol, and wherein the second average molecular weight M n,2 Selected from the range of 10000-100000 g / mol; wherein 1 <M n,1 / M n,2 ≤50.

[0060] Alternatively, in an embodiment, the first average molecular weight M n,1 The second average molecular weight Mn2 may be selected from the range of 5000-1000000 g / mol, such as 10000-100000 g / mol, in particular 25000-50000 g / mol. In particular, the second average molecular weight Mn2 may be selected from the range of 10000-1000000 g / mol, such as 60000-500000 g / mol, in particular 100000-250000 g / mol. In particular, 1≤M n,1 / M n,2 ≤50, more particularly 1 <M n,1 / M n,2 ≤50。

[0061] In an embodiment, the first material may have a first viscosity PV1. More particularly, the second material may have a second viscosity PV2. In an embodiment, PV1 may be the same as PV2. However, in other embodiments, PV1 and PV2 may be different. As previously mentioned, in particular, the first thermoplastic material and the second thermoplastic material may be selected such that 1 < PV1 / PV2 ≤ 50, such as 1 < PV1 / PV2 ≤ 500, particularly 1 < PV1 / PV2 ≤ 5000. More particularly, 10 < PV1 / PV2 ≤ 5000, such as 100 < PV1 / PV2 ≤ 5000, particularly 1000 < PV1 / PV2 ≤ 5000. Alternatively, in an embodiment, the first material may have a first viscosity PV1, where the second material may have a second viscosity PV2 different from the first viscosity PV1, where 1 < PV2 / PV1 ≤ 50, such as 1 < PV2 / PV1 ≤ 500, particularly 1 < PV2 / PV1 ≤ 5000. More particularly, 10 < PV2 / PV1 ≤ 5000, such as 100 < PV2 / PV1 ≤ 5000, particularly 1000 < PV2 / PV1 ≤ 5000. In particular, PV1 may be greater than PV2 and vice versa.

[0062] In an embodiment, the first material may have a first melt volume rate (MVR1). Additionally, in an embodiment, the second material may optionally include a second filler material. In particular, the second material may have a second melt volume rate (MVR2). As previously mentioned, the first filler material and / or the second filler material may be optional, and thus, in an embodiment, the first material and / or the second material may (also) not include the first filler material or the second filler material, respectively.

[0063] Furthermore, as previously mentioned, in an embodiment, the second melt volume rate (MVR2) may be selected from the range of 0.1 - 300 cm 3 / (10 min.), such as 1 - 30 cm 3 / (10 min.), particularly 10 - 20 cm 3 / (10 min.). In an embodiment, MVR1 and MVR2 may be selected such that 1 < MVR1 / MVR2 ≤ 0.0003, such as 1 < MVR1 / MVR2 ≤ 0.003, 1 < MVR1 / MVR2 ≤ 0.03 (according to ISO 1133 12, at 300 °C and 1.2 kg). ISO 1133 12 (which defines the dimensions, temperature, and weight) may be used, for example, to measure the amount of material flowing out per unit time (cm 3 / 10 min). The temperature and weight used during the measurement are 300°C and 1.2 kg (plunger weight), respectively, according to ISO 1133 12, as described above.

[0064] In addition, in an embodiment, the first material may further include a first filler material having a first volume percentage V1 relative to the first material. In addition, in an embodiment, the second material may further include a second filler material having a second volume percentage V2 relative to the second material. More specifically, the first filler material and the second filler material may be different filler materials. However, in an embodiment, the first filler material and the second filler material are the same material.

[0065] In an embodiment, V1 may be in the range of 0-90 vol.%, such as 5-50 vol.%, in particular 10-25 vol.%. As previously mentioned, some embodiments may not include the first filler material, and the volume percentage of the first filler material may be 0 vol.%, i.e., the core may be completely filled with the first thermoplastic material. Similarly, in an embodiment, V2 may be in the range of 0-30 vol.%, such as 0-15 vol.%, in particular 0-10 vol.%. More particularly, the second volume percentage V2 may be in the range of 5-30 vol.%, such as 10-30 vol.%, in particular 15-30 vol.%. (Also) Note that some embodiments may not include the second filler material, and therefore, the volume percentage of the second filler material may be 0 vol.%, i.e., the shell may be completely filled with the second thermoplastic material.

[0066] In an embodiment, V1 and V2 may be configured such that 0≤V2 / V1≤100, particularly 0≤V2 / V1≤10, more particularly 0≤V2 / V1≤1. More particularly, in an embodiment, V1 and V2 may be 0≤V2 / V1≤5, particularly 0≤V2 / V1≤0.5, such as 0≤V2 / V1≤0.05.

[0067] Furthermore, in an embodiment, the first thermoplastic material may have a first average molecular weight M n,1 In addition, in an embodiment, the second thermoplastic material may have a second average molecular weight M n,2 Note that, in particular, in the embodiment, M n,1 M may not be equal to n,2 , that is, M n,1 ≠M n,2 In addition, in these embodiments, M can be applied n,1 / M n,2 ≤10, such as M n,1 / M n,2 ≤50, especially M n,1 / M n,2≤100. However, as described above, other embodiments are possible. Furthermore, in an embodiment, at least one of the first material and the second filler material is selected from glass or fiber. Thus, in an embodiment, one or more of the first material and the second material may include a T of the material(s). g or T m There is (will be) no filler that has an impact, such as glass and fiber. In an embodiment, at least one of the first material and the second filler material may include one or more of light reflective particles, light transmissive particles, light absorbing particles, luminescent particles, magnetic particles, conductive particles, etc.

[0068] As described above, 3D printed objects can be used for different purposes. In addition, 3D printed objects can be used for lighting. Therefore, in another aspect, the present invention also provides a lighting device including a 3D object as defined herein. In a specific aspect, the present invention provides a lighting system, the lighting system comprising (a) a light source configured to provide (visible) light source light, and (b) a 3D object as described herein, wherein the 3D object can be configured as one or more of the following: (i) at least a portion of a shell, (ii) at least a portion of a wall of an illumination chamber, and (iii) a functional component, wherein the functional component can be selected from an optical component, a support, an electrically insulating component, a conductive component, a thermal insulation component, and a thermally conductive component. Therefore, in a specific embodiment, the 3D object can be configured as one or more of the following: (i) at least a portion of a lighting device housing, (ii) at least a portion of a wall of an illumination chamber, and (iii) an optical element. Since a relatively smooth surface can be provided, the 3D printed object can be used as a reflector or a lens, etc. In an embodiment, the 3D object can be configured as a light shield. A device or system may include multiple different 3D printed objects with different functions.

[0069] Returning to the 3D printing process, a specific 3D printer can be used to provide the 3D printed objects described herein. Therefore, on the other hand, the present invention also provides a fused deposition modeling 3D printer, the 3D printer comprising a nozzle portion configured downstream of the extruder portion, a first feeder, a second feeder and a control system. In an embodiment, the fused deposition modeling 3D printer can be configured to provide a 3D printable material to a substrate, thereby providing a 3D object comprising a 3D printable material. In addition, in an embodiment, the nozzle portion may include a core-shell nozzle, the core-shell nozzle including (i) a nozzle core configured downstream of the extruder portion. In addition, in an embodiment, the nozzle portion may include a nozzle shell (not configured downstream of the extruder portion). In addition, in an embodiment, the first feeder may be configured to deliver a granular material comprising a first 3D printable material to the extruder portion (wherein the first 3D printable material may include a first material). In an embodiment, the second feeder may be configured to deliver a filament comprising a second 3D printable material to the nozzle shell. In particular, the second 3D printable material may include a second material different from the first material. In addition, in an embodiment, the control system may be configured to perform the above method. Therefore, in a specific embodiment, the present invention can provide a fused deposition modeling 3D printer (or 3D printer), which includes an extruder part, a nozzle part configured downstream of the extruder part, a first feeder, a second feeder and a control system; wherein the fused deposition modeling 3D printer is configured to provide a 3D printable material to a substrate, thereby providing a 3D object including the 3D printable material, wherein the nozzle part includes a core-shell nozzle, the core-shell nozzle includes (i) a nozzle core configured downstream of the extruder part, and (ii) a nozzle shell (not configured downstream of the extruder part); wherein the first feeder is configured to feed a granular material including a first 3D printable material to the extruder part (wherein the first 3D printable material includes a first material); wherein the second feeder is configured to feed a filament including a second 3D printable material to the nozzle shell (wherein the second 3D printable material includes a second material different from the first material); and wherein the control system is configured to perform the above method (as described above).

[0070] In particular, the fused deposition modeling 3D printer can be configured to provide a 3D printable material to a substrate, thereby providing a 3D object comprising the 3D printed material. Thus, in this manner, embodiments of the 3D printer can be used to provide a 3D object using a 3D printing method. In particular, the 3D object can be provided by layer-by-layer deposition, wherein each layer can include a core-shell configuration. More particularly, the 3D object can include a 3D printed material, wherein the 3D printed material can include one or more different types of 3D printed materials. However, in certain embodiments, they can also be the same.

[0071] As described above, the fused deposition modeling 3D printer may include a nozzle portion, a first feeder, a second feeder, and a control system configured downstream of the extruder portion. In an embodiment, the extruder portion may provide a volume for accommodating at least a portion of a 3D printable material. In particular, the 3D printer may include a screw and a barrel, wherein the screw and the barrel may provide advantages for controlling the extrudate, i.e., the amount (or volume percentage) of the 3D printable material deposited on a receiver object or substrate to provide a 3D object. In particular, the 3D printable material may extrude the 3D printable material in a downstream direction so that the 3D printable material is deposited via the nozzle. Note that in an embodiment, a portion of the 3D printable material (also) may be directly provided to the nozzle, i.e., the 3D printable material may not be provided to the extruder volume.

[0072] In an embodiment, the nozzle portion may include a core-shell nozzle, the core-shell nozzle further comprising (i) a nozzle core configured downstream of the extruder portion. In addition, in an embodiment, the 3D printer may include a nozzle shell (not configured downstream of the extruder portion). Therefore, in this way, one or more 3D printable materials can be used to provide a 3D object. In particular, one or more 3D printable materials can be mixed within the 3D printer. More particularly, the 3D printer can provide an extrudate having a core-shell configuration from the nozzle such that the shell covers the core.

[0073] Furthermore, in an embodiment, the first feeder may be configured to feed a granular material comprising a first 3D printable material to the extruder portion. In particular, the first 3D printable material may include a first 3D printable material. In an embodiment, the 3D printer may include a second feeder, and the second feeder may be configured to feed a filament comprising a second 3D printable material to the nozzle housing. In particular, the second 3D printable material may include a second material different from the first material. Thus, a 3D printable material comprising one or more different 3D printable materials may be used to provide a 3D object, wherein the 3D object may be provided by layer-by-layer deposition of layers having a core-shell configuration.

[0074] The first feeder and / or the second feeder may provide the 3D printable material to the printer head, or may directly provide the 3D printable material, and the printer head creates a filament comprising the 3D printable material. Therefore, in an embodiment, the present invention provides a fused deposition modeling 3D printer, the 3D printer comprising (a) a printer head comprising a printer nozzle, and (b) a filament providing device configured to provide a filament comprising the 3D printable material to the printer head, wherein the fused deposition modeling 3D printer is configured to provide the above-mentioned 3D printable material to a substrate as described above and / or to a 3D (printed) object as described above.

[0075] Furthermore, in an embodiment, the 3D printer may comprise a control system. In particular, the control system may be configured to perform the method (as described above) to provide a 3D object. In particular, the 3D printer may comprise a controller (or be functionally coupled to a controller) configured to perform the method described herein in a control mode (or "operation mode"). Instead of the term "controller", the term "control system" (see above) may also be applied.

[0076] In an embodiment, the control system may be configured to control 3D printing conditions. In particular, the 3D printing conditions may control a first volume flow rate of the granular material (to the extruder portion). Furthermore, in an embodiment, the 3D printing conditions may control a second volume flow rate of the filament (to the nozzle housing). Furthermore, in an embodiment, the 3D printing conditions may control a nozzle temperature T n Thus, in certain embodiments, the control system can be configured to control a 3D printing condition; wherein the 3D printing condition is selected from: a first volume flow rate of the particulate material (to the extruder portion), (ii) a second volume flow rate of the filament (to the nozzle housing), and (iii) a nozzle temperature T n .

[0077] In an embodiment, the control system can be used to control the energy input to the extruder section. In addition, in an embodiment, the control system can control a parameter related to the particle size (d1), which parameter can be selected from: (a) particle size (d1), and (b) energy input to the extruder section.

[0078] The term "control" and similar terms particularly refer to at least determining the behavior of an element or supervising its operation. Therefore, herein, "control" and similar terms may refer to applying behavior (determining the behavior or supervising the operation of an element) to an element, such as, for example, measuring, displaying, actuating, opening, moving, changing temperature, etc. In addition, the term "control" and similar terms may also include monitoring. Therefore, the term "control" and similar terms may include applying behavior to an element, and also include imposing behavior and monitoring elements on an element. The control of an element may be performed by a control system, which may also be indicated as a "controller". Therefore, the control system and the element may be functionally coupled at least temporarily or permanently. The element may include a control system. In an embodiment, the control system and the element may not be physically coupled. Control may be performed via wired and / or wireless control. The term "control system" may also refer to a plurality of different control systems, which are particularly functionally coupled, wherein, for example, one control system may be a master control system, and one or more other control systems may be slave control systems. The control system may include or may be functionally coupled to a user interface.

[0079] The control system may also be configured to receive and execute instructions from a remote control. In an embodiment, the control system may be controlled via an App on a device, such as a portable device, such as a smartphone or I-phone, a tablet, etc. Thus, the device is not necessarily coupled to the lighting system, but may be (temporarily) functionally coupled to the lighting system.

[0080] Thus, in an embodiment, the control system may (also) be configured to be controlled by an App on a remote device. In such an embodiment, the control system of the lighting system may be a control from the control system or in slave mode. For example, the lighting system may be identifiable with a code, in particular a unique code for the respective lighting system. The control system of the lighting system may be configured to be controlled by an external control system, which may access the lighting system based on the knowledge of the (unique) code (input by a user interface with an optical sensor (e.g. a QR code reader)). The lighting system may also include components for communicating with other systems or devices, such as based on Bluetooth, WIFI, LiFi, ZigBee, BLE or WiMAX or another wireless technology.

[0081] The system, device or equipment may perform actions in a "mode" or "operating mode" or "operating mode". Similarly, in a method, an action or phase or step may act in a "mode" or "operating mode" or "operating mode" or "operable mode". The term "mode" may also be expressed as a "control mode". This does not exclude that the system, device or equipment may also be adapted to provide another control mode or multiple other control modes. Similarly, this may not exclude that one or more other modes may be executed before and / or after executing the mode.

[0082] However, in an embodiment, a control system may be provided, which is adapted to provide at least a control mode. If other modes are available, the selection of such a mode may in particular be performed via a user interface, although other options (such as executing a mode according to a sensor signal or a (time) scheme) are also possible. In an embodiment, an operating mode may also refer to a system, device or apparatus that can only be operated in a single operating mode (i.e. "on", without further adjustability).

[0083] Therefore, in an embodiment, the control system may be controlled according to one or more of an input signal of a user interface, a sensor signal (of a sensor) and a timer.The term "timer" may refer to a clock and / or a predetermined time scheme.

[0084] The abbreviation "3D printer", "FDM printer" or "printer" may be used instead of "fused deposition modeling (FDM) 3D printer". The printer nozzle may also be called a "nozzle" and sometimes an "extruder nozzle". BRIEF DESCRIPTION OF THE DRAWINGS

[0085] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which corresponding reference characters indicate corresponding parts, and in which:

[0086] 1a-1c schematically depict some general aspects of embodiments of a 3D printer and 3D printing materials;

[0087] 2a-2d schematically depict some embodiments and aspects related to a method for producing a 3D printed object 1 , a 3D printed object 1 and a 3D printer 500 ;

[0088] Figure 3 An application, such as a lighting device, is schematically depicted.

[0089] The schematic diagrams are not necessarily drawn to scale. DETAILED DESCRIPTION

[0090] Figure 1a schematically depicts some aspects of a 3D printer. Reference numeral 500 indicates a 3D printer. Reference numeral 530 indicates a functional unit configured for 3D printing, in particular FDM 3D printing; the reference numeral may also indicate a 3D printing table unit. Here, only a printer head for providing 3D printing material, such as an FDM 3D printer head, is schematically depicted. Reference numeral 501 indicates a printer head. The 3D printer of the present invention may in particular include a plurality of printer heads (see below). Reference numeral 502 indicates a printer nozzle. The 3D printer of the present invention may in particular include a plurality of printer nozzles, but other embodiments are also possible. Reference numeral 320 indicates a filament (as described above) that can print a 3D printable material.

[0091] In addition to filaments, pellets can also be used as 3D printable materials. Both can be extruded through a printer nozzle.

[0092] For the sake of clarity, not all features of the 3D printer are depicted, only features that are particularly relevant to the present invention (see also below). Reference numeral 321 denotes an extrudate (of the 3D printable material 201 ).

[0093] The 3D printer 500 is configured to generate a 3D object 1 by depositing a plurality of layers 322 layer by layer on a receiver object 550, which in an embodiment can be at least temporarily cooled, wherein each layer 322 comprises a 3D printable material 201, such as a 3D printable material having a melting point T m. The 3D printable material 201 may be deposited on the substrate 1550 (at the printing stage). By being deposited, the 3D printable material 201 has become the 3D printing material 202. The 3D printable material 201 escaping from the nozzle 502 is also indicated as extrudate 321. Reference numeral 401 indicates a thermoplastic material.

[0094] The 3D printer 500 may be configured to heat the filament 320 material upstream of the printer nozzle 502. This may be done, for example, by a device comprising one or more of an extrusion and / or heating function. Such a device is indicated by reference numeral 573 and is arranged upstream of the printer nozzle 502 (i.e., at a time before the filament material leaves the printer nozzle 502). The printer head 501 may (thus) include a liquefier or a heater. Reference numeral 201 indicates a printable material. When deposited, the material is indicated as a (3D) printing material, which is indicated by reference numeral 202.

[0095] Reference numeral 572 indicates a reel or roller with material, in particular in the form of a wire, which can be indicated as filament 320. The 3D printer 500 converts it into an extrudate 321 downstream of the printer nozzle, which becomes a layer 322 on the receiver object or the already deposited printing material. Typically, the diameter of the extrudate 321 downstream of the nozzle 502 is reduced relative to the diameter of the filament 322 upstream of the printer head 501. Therefore, the printer nozzle is sometimes (also) indicated as an extruder nozzle. By arranging layer 322 layer by layer 322 and / or on layer 322, a 3D object 1 can be formed. Reference numeral 575 indicates a filament providing device, which here, among other things, includes a reel or roller indicated by reference numeral 576 and a drive wheel.

[0096] Reference symbol Ax indicates the longitudinal axis or filament axis.

[0097] Reference numeral 300 schematically depicts a control system. The control system may be configured to control the 3D printer 500. The control system 300 may include or be functionally coupled to the 3D printer 500. The control system 300 may also include or be functionally coupled to a temperature control system configured to control the temperature of the receiver object 550 and / or the printer head 501. Such a temperature control system may include a heater capable of heating the receiver object 550 to a temperature of at least 50°C, but in particular in the range of up to about 350°C, such as at least 200°C.

[0098] Alternatively or additionally, in embodiments, the receiver plate may also be movable in one or both directions in the xy plane (horizontal plane). Furthermore, alternatively or additionally, in embodiments, the receiver plate may also be rotatable about the z axis (vertical). Thus, the control system may move the receiver plate in one or more of the x-direction, the y-direction, and the z-direction.

[0099] Alternatively, the printer can have a printer head that can also rotate during printing. The advantage of this printer is that the printed material cannot rotate during printing.

[0100] The layer is indicated by reference numeral 322 and has a layer height H and a layer width W.

[0101] Note that the 3D printable material is not necessarily provided to the printer head as filament 320. In addition, filament 320 can also be made from multiple pieces of 3D printable material in 3D printer 500.

[0102] Reference symbol D indicates the diameter of the nozzle (through which the 3D printable material 201 is forced).

[0103] FIG1 b schematically depicts the printing of the 3D object 1 being constructed in more detail in 3D form. Here, in this schematic diagram, the ends of the filament 321 in a single plane are not connected to each other, although in practice this may be the case in embodiments. Reference numeral H indicates the height of the layer. The layers are indicated by reference numeral 203. Here, the layers have a substantially circular cross-section. However, they may be generally flat, such as having a profile similar to a flat oval tube or a flat oval pipe (i.e., a round rod with a diameter compressed to a height less than the width, wherein the sides (defining the width) are (still) circular).

[0104] Thus, Figures 1a-1b schematically depict aspects of a fused deposition modeling 3D printer 500, which includes (a) a first printer head 501 including a printer nozzle 502, (b) a filament providing device 575 configured to provide a filament 321 including a 3D printable material 201 to the first printer head 501, and optionally (c) a receiver object 550. In Figures 1a-1b, the first printable material or the second printable material or the first printing material or the second printing material is indicated by the general indications printable material 201 and printing material 202, respectively. Immediately downstream of the nozzle 502, the filament 321 having the 3D printable material becomes a layer 322 having the 3D printing material 202 when deposited.

[0105] Figure 1c schematically depicts a stack of 3D printed layers 322, each layer having a layer height H and a layer width W. Note that in embodiments, the layer width and / or layer height of two or more layers 322 may be different. Reference numeral 252 in Figure 1c indicates an object surface of the 3D object (schematically depicted in Figure 1c).

[0106] 1a-1c, the deposited filaments of 3D printable material produce layers of height H (width W). Layer 322 is deposited after layer 322, resulting in a 3D object 1. A single-walled 3D object 1 is depicted very schematically in FIG1c.

[0107] 2a - 2d schematically depict some embodiments and aspects related to a method for producing a 3D printed object 1 , a 3D printed object 1 and a 3D printer 500 .

[0108] 2a schematically depicts an embodiment of a fused deposition modeling 3D printer 500, which includes an extruder portion 510, a nozzle portion 520 configured downstream of the extruder portion 510, a first feeder 530, a second feeder 540, and a control system 300. In particular, the fused deposition modeling 3D printer 500 can be configured to provide a 3D printable material 201 to a substrate 1550, thereby providing a 3D object 1 including a 3D printing material 202.

[0109] In an embodiment, the extruder portion may include a barrel 580 and a screw 585. In an embodiment, the nozzle portion 520 may include a core-shell nozzle 502, which (also) includes (i) a nozzle core 521 configured downstream of the extruder portion 510, and (ii) a nozzle shell 522 (not configured downstream of the extruder portion 510). In addition, in an embodiment, the first feeder 530 may be configured to feed a granular material 531 including a first 3D printable material 1201 to the extruder portion 510 (wherein the first 3D printable material 1201 includes a first material 1211).

[0110] Furthermore, in an embodiment, the second feeder 540 may be configured to feed the filament 320 including the second 3D printable material 2201 to the nozzle housing 522 (wherein the second 3D printable material 2201 includes a second material 2211 different from the first material 1211). Furthermore, in an embodiment, the control system 300 may be configured to perform the method.

[0111] In an embodiment, the control system 300 can be configured to control 3D printing conditions. In particular, the 3D printing conditions can be selected from: (i) a first volume flow rate of the granular material 531 (to the extruder portion 510), (ii) a second volume flow rate of the filament 320 (to the nozzle housing 522), and (iii) a nozzle temperature Tn .

[0112] In addition, in some embodiments, the control system 300 can be configured to monitor a parameter related to the particle size (d1) of the granular material 531, and control the 3D printing conditions according to the parameter related to the particle size (d1). In particular, the parameter related to the particle size (d1) is selected from: (a) particle size (d1), (b) energy input to the extruder portion 510.

[0113] Among other things, the present invention may provide a method for producing a 3D object 1 by fused deposition modeling. In particular, the method may include a 3D printing phase, which uses a fused deposition modeling 3D printer 500 to deposit a 3D printable material 201 layer by layer to provide a 3D object 1 including a layer 322 of 3D printing material 202.

[0114] In an embodiment, the 3D printer 500 may include an extruder portion 510, a nozzle portion 520 configured downstream of the extruder portion 510, a first feeder 530, and a second feeder 540. In addition, in an embodiment, the nozzle portion 520 may include a core-shell nozzle 502, the core-shell nozzle including (i) a nozzle core 521 configured downstream of the extruder portion 510 and (ii) a nozzle shell 522 (not configured downstream of the extruder portion 510). In addition, in an embodiment, the first feeder 530 may be configured to feed a granular material 531 including a first 3D printable material 1201 to the extruder portion 510, wherein the first 3D printable material 1201 may include a first material 1211. In addition, the second feeder 540 may be configured to feed a filament 320 including a second 3D printable material 2201 to the nozzle shell 522. In particular, the second 3D printable material 2201 may include a second material 2211 different from the first material 1211.

[0115] In an embodiment, the 3D printing stage may include: (i) feeding the particulate material 531 to the extruder portion 510 and feeding the filament 320 to the nozzle shell 522, (ii) generating a core-shell extrudate 321 via the core-shell nozzle 502, and (iii) depositing the core-shell extrudate 321 to provide a 3D printed material 202 including a core 330 and a shell 340, the 3D printed material at least partially surrounding the core 330. More specifically, the core 330 may include a first material 1211, and the shell 340 may include a second material 2211.

[0116] In addition, in an embodiment, the first material 1211 may include a first thermoplastic material 351, and the second material 2211 may include a second thermoplastic material 351. This may be due to the availability of one or more corresponding thermoplastic materials and filler materials. In particular, the first material 1211 and the second material 2211 may have different viscosities. In addition, in an embodiment, the first thermoplastic material 351 and the second thermoplastic material 352 may be different, such as in terms of viscosity, transition temperature, molecular weight, volume percentage, etc.

[0117] Thus, in an embodiment, the first thermoplastic material 351 may have a first transition temperature T selected from a first glass transition temperature T g,1 and a first melting temperature T m,1 of. More particularly, the second thermoplastic material 352 may have a second transition temperature T selected from a second glass transition temperature T t,1 . g,2 and a second melting temperature T m,2 of. In an embodiment, the method may include controlling a nozzle temperature T t,2 , where during at least a portion of the 3D printing stage, T n > T n and T t,1 > T n apply. In particular, T t,2 ≥ (T n + 10 °C) and T m,1 ≥ (T n + 10 °C), and more particularly, T m,2 ≥ (T n + 100 °C) and T m,1 ≥ (T n + 100 °C). m,2

[0118] Still referring to FIG. 2b, further, in an embodiment, the first material 1211 may optionally include a first filler material 361. In particular, the first material 1211 may have a first melt volume rate (MVR1). In an embodiment, the second material 2211 may optionally include a second filler material 362. More particularly, the second material 1211 may have a second melt volume rate (MVR2). In an embodiment, the first melt volume rate (MVR1) may be selected from the range of 0.1-1 cm 3 / (10 min.). In addition, in an embodiment, the second melt volume rate (MVR2) may be selected from the range of 1-30 cm 3 / (10 min.). In particular, 1 < MVR1 / MVR2 ≤ 0.003 (according to ISO 1133 12, at 300 °C and 1.2 kg).

[0119] In an embodiment, the first thermoplastic material 351 may have a first average molecular weight M n,1 , and the second thermoplastic material 352 may have a second average molecular weight M n,2 . The definition of molecular weight is as described above and is measured in g / mol. In an embodiment, the first average molecular weight M n,1 may be selected from the range of 60,000 - 500,000 g / mol, and wherein the second average molecular weight M n,2 may be selected from the range of 10,000 - 100,000 g / mol. More particularly, 1 < M n,1 / M n,2 ≤ 50.

[0120] Alternatively, in an embodiment, the first thermoplastic material 351 may have a first average molecular weight M n,1 , and the second thermoplastic material 352 may have a second average molecular weight M n,2 . Particularly, the first average molecular weight M n,1 may be selected from the range of 10,000 - 100,000 g / mol, and the second average molecular weight M n,2 may be selected from the range of 60,000 - 500,000 g / mol. Particularly, 1 < M n,1 / M n,2 ≤ 50.

[0121] As described above, in an embodiment, the first material 1211 may have a first viscosity PV1, and the second material 2211 may have a second viscosity PV2 different from the first viscosity PV1. Particularly, 1 < PV1 / PV2 ≤ 500. Alternatively, in an embodiment, 1 < PV2 / PV1 ≤ 500.

[0122] Furthermore, the 3D printer 500 may use a 3D printing method (as described above) to provide the 3D object 1. In an embodiment, the 3D object 1 may be provided by the layer-by-layer deposition of the 3D printable material 1201. Thus, in this way, in an embodiment, a 3D object including layers of the 3D printing material 202 may be provided.

[0123] As previously mentioned, the 3D object 1 may include a 3D printing material 202 that includes a first thermoplastic material 351 and a second thermoplastic material 352. Particularly, the first thermoplastic material 351 may have a first transition temperature T g,1 selected from a first glass transition temperature T m,1 and a first melting temperature T t,1 .

[0124] Furthermore, in an embodiment, the first material 1211 may optionally include a first filler material 361. Likewise, in an embodiment, the second material 2211 may optionally include a second filler material 362.

[0125] Thus, in an embodiment, the granular material 531 fed to the extruder may include a first thermoplastic material and a first filler material embedded in the first thermoplastic material, wherein the first filler material may include a particulate filler material. Thus, the granules 531 may include smaller filler material particles.

[0126] FIG. 2 b schematically depicts two embodiments of layers comprised by a 3D object 1, which also comprises a 3D printing material 202. In this embodiment, in particular, the plurality of layers 322 may be different. In an embodiment, the first material 1211 may comprise a first thermoplastic material 351, and the second material 2211 may comprise a second thermoplastic material 352. In particular, the first material 1211 (i.e., the core 330 of the intermediate layer 322 in this embodiment) may comprise a (particulate) first filler material 361, while the other layers may not comprise such a first filler material 361. Furthermore, in an embodiment, the second material 2211 (i.e., the shell 340 of the intermediate layer 322 in this embodiment) may comprise a second filler material 362. Note that embodiment I depicts a (highly) filled first material, i.e., the core 330 may comprise a high volume percentage concentration (such as 50 vol.%) of the first filler material 361.

[0127] Embodiment II depicts an embodiment of layers included in a 3D object 1, which also includes a 3D printing material 202. Embodiment II may be similar to Embodiment I, and for the sake of brevity, these details will not be repeated. However, the features of the embodiment do not limit the scope of the features of Embodiment II in any way. In particular, Embodiment II depicts a 3D object 1 including a first material 1211 and a second material 2211, which also includes a first material 351 and a second material 352. In this embodiment, a top layer 322 may include a first material 1211 and a second material 2211, the first material including a first filler material 361 (i.e., within the core 330), and the second material including a second filler material 362 (i.e., within the shell 340). Note that Embodiment II depicts a (highly) filled first material, i.e., the core 330 may include a low volume percentage concentration (such as 15 vol.%) of the first filler material 361.

[0128] Note that in embodiments, the first material 1211 and the second material 2211 may differ in one or more of the molecular weight, viscosity, chemical composition, filler material, and filler material concentration of the thermoplastic material. Thus, in embodiments, the first thermoplastic material 351 may have a first average molecular weight M n,1, and the second thermoplastic material 352 may have a second average molecular weight M n,2 In particular, the first average molecular weight M n,1 can be selected from the range of 60000-500000 g / mol, and the second average molecular weight M n,2 can be selected from the range of 10000-100000 g / mol. More particularly, 1 <M n,1 / M n,2 ≤50. Alternatively, in an embodiment, the first average molecular weight M n,1 can be selected from the range of 10000-100000 g / mol, and the second average molecular weight M n,2 Can be selected from the range of 60000-500000 g / mol. More particularly, in such an embodiment, 1 <M n,1 / M n,2 ≤50. In addition, the first thermoplastic material 351 and the second thermoplastic material 352 may be selected such that M n,1 ≠M n,2 ≤50. In particular, at least one of the (particulate) first filler material 361 and the (particulate) second filler material 362 may be selected from glass or fiber.

[0129] In an embodiment, the first material 1211 may include a first filler material 361 having a first volume percentage V1 relative to the first material 1211, and the second material 2211 may optionally include a second filler material 362 having a second volume percentage V2 relative to the second material 2211. In particular, the first volume percentage V1 may be selected from the range of 5-50 vol.%, and the second volume percentage V2 may be selected from the range of 0-15 vol.%, and wherein 0≤V2 / V1≤0.5.

[0130] Furthermore, in an embodiment, the first material 1211 may include a first filler material 361 having a first volume percentage V1 relative to the first material 1211, and the second material 2211 may include a second filler material 362 having a second volume percentage V2 relative to the second material 2211. In particular, the first filler material 361 and the second filler material 362 may be different filler materials. Furthermore, in an embodiment, the first material 1211 may include a first filler material 361 having a first volume percentage V1 (relative to the first material 1211), and the second material 2211 may include a second filler material 362 having a second volume percentage V2 (relative to the second material 2211). In particular, the first filler material 361 and the second filler material 362 may be different filler materials.

[0131] FIG. 2c schematically depicts an embodiment of a granular material 531. In particular, the core can be based on the granular material fed to the extruder section. More particularly, the granular material can include a particle size d1, which can be a diameter, a length, etc. In an embodiment, d1 can be a granular material diameter for a spherical granular material. However, alternatively or additionally, the parameter d1 can be the major axis or the minor axis of the elliptical granular material 531. In other embodiments, d1 can (also) be a length, a width, a height, etc.

[0132] Furthermore, in an embodiment, the method may include monitoring a parameter related to a particle size d1 of the granular material 531, and controlling the 3D printing conditions according to the parameter related to the particle size d1. In particular, the parameter related to the particle size d1 may be selected from: (a) the particle size d1, and (b) the energy input to the extruder portion 510.

[0133] FIG2d schematically depicts a 3D printable material 201 (and / or 3D printing material 202) including a core 330, the core further comprising a first thermoplastic material 351. In addition, in embodiments, the 3D printable material 201 (and / or 3D printing material 202) may include a shell 340, the shell further comprising a second thermoplastic material 352. In particular, the surface of the core 330 and / or the shell 340 may not be smooth. Thus, in certain embodiments, the surface of the core 330 may have a first deviation R1, while the surface of the shell 340 may have a second deviation R2. As a result, in embodiments, the core 330 and the shell 340 may have perimeters p1 and p2, respectively.

[0134] In an embodiment of a 3D object, the 3D object 1 may include a layer 322 of a 3D printed material 202. In particular, the layer 322 may include a core-shell cross-section including a core 330 and a shell 340, the shell at least partially surrounding the core 330. More particularly, the core 330 may include a first material 1211, and the shell 340 may include a second material 2211 different from the first material 1211. In an embodiment, the core 330 may have a first perimeter p1 with a first deviation R1, thereby defining a first root mean square roughness RMS1, and the shell 340 may have a second perimeter p2 with a second deviation R2, thereby defining a second root mean square roughness RMS2. In particular, RMS1 / RMS2≤0.5.

[0135] Figure 3An embodiment of a lamp or luminaire indicated by reference numeral 2 is schematically depicted, comprising a light source 10 for generating light 11. The lamp may comprise a housing or a light shield or another element, which may comprise or be a 3D printed object 1. Here, a hemisphere (cross-sectional view) schematically indicates the housing or the light shield. The lamp or luminaire may be or may comprise a lighting device 1000 (which comprises the light source 10). Thus, in a particular embodiment, the lighting device 1000 comprises a 3D object 1. The 3D object 1 may be configured as one or more of: (i) at least a portion of a lighting device housing, (ii) at least a portion of a wall of a lighting chamber, and (iii) an optical element. Thus, in an embodiment, the 3D object may be reflective to the light source light 11 and / or transmissive to the light source light 11. Here, the 3D object may be, for example, a housing or a light shield. The housing or the light shield comprises an object portion 400. See also above for possible embodiments of the object portion 400.

[0136] The term "plurality" means two or more.

[0137] Those skilled in the art will understand the terms "substantially" or "substantially" and similar terms herein. The terms "substantially" or "substantially" may also include embodiments with "complete", "completely" or "all", etc. Therefore, in an embodiment, the adjective "substantially" or "substantially" may also be deleted. Where applicable, the term "substantially" or the term "substantially" may also relate to 90% or higher, such as 95% or higher, particularly 99% or higher, even more particularly 99.5% or higher (including 100%).

[0138] The term "comprise" also includes embodiments wherein the term "comprises" means "consist of."

[0139] The term "and / or" specifically relates to one or more items mentioned before and after "and / or". For example, the expression "item 1 and / or item 2" and similar expressions may relate to one or more items of item 1 and item 2. In one embodiment, the term "comprising" may refer to "consisting of", but in another embodiment, it may also refer to "including at least the defined categories and optionally one or more other categories".

[0140] In addition, the terms first, second, third, etc. in the specification and claims are used to distinguish similar elements and not necessarily to describe a sequential or chronological order. It should be understood that the terms so used are interchangeable under appropriate circumstances, and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

[0141] Devices, apparatuses or systems etc. may be described herein during operation. It will be clear to those skilled in the art that the present invention is not limited to methods of operation or devices, apparatuses or systems in operation.

[0142] It should be noted that the above-mentioned embodiments illustrate rather than limit the invention, and that those skilled in the art will be able to design many alternative embodiments without departing from the scope of the appended claims.

[0143] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

[0144] The use of the verb "to comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the specification and claims, the words "comprise", "comprising" and the like should be interpreted as being inclusive and not exclusive or exhaustive; that is, in the sense of "including but not limited to".

[0145] The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0146] The invention may be implemented by means of hardware comprising several distinct elements and a suitably programmed computer. In a device claim, an apparatus claim or a system claim enumerating several means, several of these means may be implemented by the same hardware. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

[0147] The present invention also provides a control system that can control a device, apparatus or system, or can perform a method or process described herein. In addition, the present invention also provides a computer program product that, when run on a computer functionally coupled to or composed of a device, apparatus or system, controls one or more controllable elements of such a device, apparatus or system.

[0148] The present invention is also applicable to a device, apparatus or system comprising one or more features described in the specification and / or shown in the drawings. The present invention also relates to a method or process comprising one or more features described in the specification and / or shown in the drawings.

[0149] The various aspects discussed in this patent can be combined to provide additional advantages. In addition, those skilled in the art will appreciate that the embodiments can be combined, and more than two embodiments can also be combined. In addition, some features can form the basis of one or more partition applications.

Claims

1. A method for producing a 3D object (1) by fused deposition modeling, the method comprising a 3D printing phase, the 3D printing phase using a fused deposition modeling 3D printer (500) to deposit a 3D printable material (201) layer by layer to provide the 3D object (1) comprising a layer (322) of 3D printing material (202); wherein: The 3D printer (500) comprises an extruder portion (510), a nozzle portion (520) arranged downstream of the extruder portion (510), a first feeder (530) and a second feeder (540); wherein: The nozzle section (520) includes a core-shell nozzle (502), the core-shell nozzle including (i) a nozzle core (521) disposed downstream of the extruder section (510) and (ii) a nozzle shell (522); The first feeder (530) is configured to feed a granular material (531) comprising a first 3D printable material (1201) to the extruder portion (510), wherein the first 3D printable material (1201) comprises a first material (1211); The second feeder (540) is configured to feed a filament (320) comprising a second 3D printable material (2201) to the nozzle housing (522), wherein the second 3D printable material (2201) comprises a second material (2211) different from the first material (1211); The 3D printing stage includes: delivering the particulate material (531) to the extruder section (510) and delivering the filament (320) to the nozzle housing (522); generating a core-shell extrudate (321) via the core-shell nozzle (502); The core-shell extrudate (321) is deposited to provide the 3D printed material (202) comprising a core (330) and a shell (340), the 3D printed material at least partially surrounding the core (330), wherein the core (330) comprises the first material (1211), and wherein the shell (340) comprises the second material (2211).

2. The method according to claim 1, wherein the first material (1211) comprises a first thermoplastic material (351), and wherein the second material (2211) comprises a second thermoplastic material (352) different from the first thermoplastic material (351); wherein the first material (1211) and the second material (2211) differ in one or more of the molecular weight, viscosity, chemical composition, filler material, and filler material concentration of the thermoplastic material.

3. The method according to claim 2, wherein the first thermoplastic material (351) has a first average molecular weight M n,1 , and wherein the second thermoplastic material (352) has a second average molecular weight M n,2 , wherein the first average molecular weight M n,1 is selected from the range of 60000-500000 g / mol, and wherein the second average molecular weight M n,2 Selected from the range of 10000-100000 g / mol; wherein 1 <M n,1 / M n,2 ≤50.

4. The method according to any one of the preceding claims 2 to 3, wherein the first thermoplastic material (351) has a first glass transition temperature T selected from g,1 and the first melting temperature T m,1 The first transition temperature T t,1 , wherein the second thermoplastic material (352) has a second glass transition temperature T selected from g,2 and the second melting temperature T m,2 The second transition temperature T t,2 , wherein the method comprises controlling the nozzle temperature T n , wherein during at least a portion of the 3D printing phase, T n >T t,1 and T n >T t,2 Applicable.

5. A method according to any one of the preceding claims, wherein the first material (1211) includes a first filler material (361) having a first volume percentage V1 relative to the first material (1211), and wherein the second material (2211) optionally includes a second filler material (362) having a second volume percentage V2 relative to the second material (2211), wherein the first volume percentage V1 is selected from the range of 5-50 vol.%, wherein the second volume percentage V2 is selected from the range of 0-15 vol.%, and wherein 0≤V2 / V1≤0.

5.

6. A method according to any of the preceding claims, wherein the first material (1211) includes a first filler material (361) having a first volume percentage V1 relative to the first material (1211), and wherein the second material (2211) includes a second filler material (362) having a second volume percentage V2 relative to the second material (2211), wherein the first filler material (361) and the second filler material (362) are different filler materials.

7. The method according to any of the preceding claims, further comprising a control system (300), wherein the control system (300) is configured to control 3D printing conditions; wherein the 3D printing conditions are selected from: (i) a first volume flow rate of the particulate material (531), (ii) a second volume flow rate of the filament (320), and (iii) a nozzle temperature T according to claim 4 n .

8. A 3D object (1), comprising a 3D printed material (202), wherein the 3D object (1) comprises a layer (322) of the 3D printed material (202), wherein the layer (322) comprises a core-shell cross section, the core-shell cross section comprises a core (330) and a shell (340), the shell at least partially surrounding the core (330), wherein the core (330) comprises a first material (1211), and wherein the shell (340) comprises a second material (2211) different from the first material (1211), wherein the core (330) has a first perimeter (p1), the first perimeter has a first deviation (R1), thereby defining a first root mean square roughness (RMS1), wherein the shell (340) has a second perimeter (p2), the second perimeter has a second deviation (R2), thereby defining a second root mean square roughness (RMS2), wherein RMS1 / RMS2≤0.

5.

9. The 3D object (1) according to claim 8, wherein the first material (1211) comprises a first thermoplastic material (351), and wherein the second material (2211) comprises a second thermoplastic material (352) different from the first thermoplastic material (351); wherein the first thermoplastic material (351) and the second thermoplastic material (352) differ in one or more of the molecular weight, viscosity, chemical composition, filler material, and filler material concentration of the thermoplastic material.

10. The 3D object (1) according to any one of claims 8 and 9, wherein the first thermoplastic material (351) has a first glass transition temperature T selected from g,1 and the first melting temperature T m,1 The first transition temperature T t,1 , wherein the second thermoplastic material (352) has a second glass transition temperature T selected from g,2 and the second melting temperature T m,2 The second transition temperature T t,2 .

11. A 3D object (1) according to any one of claims 8 and 10, wherein the first material (1211) includes a first filler material (361) having a first volume percentage V1 relative to the first material (1211), and wherein the second material (2211) optionally includes a second filler material (362) having a second volume percentage V2 relative to the second material (2211), wherein the first volume percentage V1 is selected from the range of 5-50 vol.%, wherein the second volume percentage V2 is selected from the range of 0-15 vol.%, and wherein 0≤V2 / V1≤0.

5.

12. The 3D object (1) according to claim 9, wherein the first thermoplastic material (351) has a first average molecular weight M n,1 , and wherein the second thermoplastic material (352) has a second average molecular weight M n,2 , M n,1 ≠M n,2 ≤50, wherein at least one of the first material (1211) and the second filler material (362) is selected from glass and fiber.

13. A lighting device (1000), comprising a 3D object (1) according to any one of the preceding claims 8 to 12, wherein the 3D object (1) is configured as one or more of (i) at least a portion of a lighting device housing, (ii) at least a portion of a wall of a lighting chamber, and (iii) an optical element.

14. A fused deposition modeling 3D printer (500), comprising an extruder portion (510), a nozzle portion (520) arranged downstream of the extruder portion (510), a first feeder (530), a second feeder (540) and a control system (300); wherein the fused deposition modeling 3D printer (500) is configured to provide a 3D printable material (201) to a substrate (1550), thereby providing a 3D object (1) comprising the 3D printing material (202), wherein: The nozzle section (520) includes a core-shell nozzle (502), the core-shell nozzle including (i) a nozzle core (521) disposed downstream of the extruder section (510) and (ii) a nozzle shell (522); The first feeder (530) is configured to feed a granular material (531) including a first 3D printable material (1201) to the extruder portion (510); The second feeder (540) is configured to feed a filament (320) comprising a second 3D printable material (2201) to the nozzle housing (522); and The control system (300), wherein the control system (300) is configured to perform the method according to any one of the preceding claims 1 to 7.

15. The fused deposition modeling 3D printer (500) according to claim 14, wherein the control system (300) is configured to control 3D printing conditions; wherein the 3D printing conditions are selected from: (i) a first volume flow rate of the granular material (531), (ii) a second volume flow rate of the filament (320), and (iii) a nozzle temperature T n .

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