Three-dimensional printable foam

Abstract

The present disclosure provides an expandable foam composition that is additively manufactured and printable. The foam composition comprises a coreactive composition and an expandable filler. Optionally, the foam composition may comprise at least one additive. The coreactive composition may be one of polyurea, Aza-Michael addition, epoxy-amine, polyurethane, polysulfide, polythioether, platinum cured silicone, condensation cured silicone, or any other suitable coreactive chemistry disclosed herein.

Description

THREE-DIMENSIONAL PRINTABLE FOAMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 63 / 553,177 entitled “3D PRINTED SOUND DAMPENING MATERIALS”, filed on February 14th, 2024, which is incorporated by reference in its entirety.GOVERNMENT LICENSE RIGHTS

[0002] This invention was made with government support under Government Contract No. W91 INF- 17-2-0227 (Army Research Laboratory, US ARMY). The government may have certain rights in the invention.FIELD

[0001] The present disclosure relates to an additively manufactured foam composition and methods for making and using the same.BACKGROUND

[0002] The additive manufacturing of foam compositions has traditionally been accomplished via numerous methods, such as fused deposition molding (FDM) and selective laser sintering (SLS). However, foam compositions additively manufactured through reactive additive manufacturing are highly limited, often time relying on blowing agents such as water, and / or volatile liquids and gasses. Such processes pose significant drawbacks, and particularly relating to coreactive extrusion, where controllability of the foam composition is highly limited.

[0003] For instance, it may be difficult to control the shape of expandable foams during application and expansion, therefore limiting the ability to additively manufacture articles from the foam composition. What is needed is a solution to the foregoing, and particularly, a controllable expandable foam for reactive extrusion-type additive manufacturing.SUMMARY

[0004] The present disclosure provides a method of additively manufacturing an object. The method includes mixing a foam composition; extruding the foam composition to form aprinted foam object; curing the foam object; and activating the foam object to form an expanded foam object. The foam composition includes a corcactivc composition and an expandable filler.

[0005] The present disclosure also provides a printable foam for additive manufacturing. The printable foam includes a coreactive composition and an expandable filler.

[0006] The present disclosure further provides an additively manufactured part. The additively manufactured pail includes a coreactive composition and an expandable filler.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description taken in conjunction with the accompanying drawings. These above-mentioned and other features of the disclosure may be used in any combination or permutation.

[0008] FIG 1A illustrates two additively manufactured printed inactivated foam objects; and

[0009] FIG. IB shows the objects in FIG. 1A after activation resulting in the expanded activated foam objects.

[0010] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate the disclosure, and such exemplifications are not to be construed as limiting the scope of the disclosure in any manner.DETAILED DESCRIPTION

[0011] The present disclosure provides a coreactive foam composition that includes expandable fillers, which are included in the coreactive composition prior to extrusion. Once extruded, the expandable filler is activated, resulting in a controlled expansion rate and extent, enabling the printing of complex 3D foam objects from coreactive compositions.I. Definitions

[0012] For purposes of the following detailed description, it is to be understood that the disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. Moreover, other than in any operating examples or where otherwise indicated, all numbers expressing, for example, quantities of ingredients used in the specificationand claims are to be understood as being modified in all instances by the term "about." For example, numerical ranges provided for weight percentages of components or amounts of components added should be construed as being modified by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties to be obtained by the present disclosure. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0013] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0014] Whereas particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from what is defined in the appended claims.

[0015] Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of " 1 to 10" is intended to include all sub-ranges from (and including) the recited minimum value of 1 to the recited maximum value of 10, that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10.

[0016] The use of the singular includes the plural and plural encompasses singular, unless specifically stated otherwise. In addition, the use of "or" means "and / or" unless specifically stated otherwise, even though "and / or" may be explicitly used in certain instances.

[0017] Ambient conditions” or “room temperature” are used herein to describes temperature values as low as 20 °C, 23 °C, or 25 °C, as high as 27 °C, 29 °C, or 30 °C, or between any of the foregoing values used as endpoints, such as between 20 °C and 30 °C , or 23 °C and 27 °C; pressure values as low as 0.85 atm, 0.90 atm, or as high as 1.0 atm, 1.02 atm, or 1.05 atm, or between any of the foregoing values used as endpoints, such as between 0.85 atm and 1.05 atm,or 0.95 atm and 1 .05 atm; and relative humidity values as low as 25% RH, 35% RH or 50% RH, as high as 75% RH, 85% RH, 90% RH, or 95% RH, or between any of the foregoing values used as endpoints, such as between 25% RH and 95% RH or between 50% RH and 75% RH.

[0018] ‘Coreactive composition” refer to the reaction product produced from the chemical interaction and reaction between at least two coreactive components (e.g., a first coreactive component, a second coreactive component, etc.).

[0019] ‘Coreactive component” refers to a compound containing at least one reactive functional group, that when physically combined with a second reactive functional group, interacts and reacts with the second reactive functional group to form a coreactive composition.II. Coreactive Chemistries

[0020] Additive manufacturing using coreactive compositions, also referred to as ambient reactive extrusion, or ARE type three-dimensional printing, typically utilizes at least two components that react with each other (e.g., are coreactive). A first coreactive component (sometimes referred to herein as a first reactant group, a first reactive functional group, part A) and at least one second coreactive component (sometimes referred to herein as a second reactant group, second reactive functional group, part B), when extruded in combination and / or succession, chemically react with one another to form a coreactive composition. The coreactive composition may thereafter cure under ambient conditions or, depending on the chemistry of the reaction, with the assistance of, for example, heat, actinic radiation, catalysts, addition of curing agents-post extrusion, etc. to form an object, or a portion of an object, comprising a thermosetting polymer (sometimes referred to as a thermoset), a thermoplastic polymer, or combinations thereof. At least the first coreactive component and the second coreactive component are chosen by one skilled in the art to result in the desired final product (e.g., thermoset, thermoplastic, etc.).

[0021] Three dimensional objects formed from coreactive compositions are additively manufactured by extruding the coreactive composition, which may be in an at least partially reacted state, onto a surface, such as a build platform. The coreactive composition may be in an at least partially reacted state at the time of extrusion and thereafter fully react and cure to form a layer of the coreactive composition. Successive layers of either the same, or different coreactive compositions can be deposited, forming additional layers of material. The coreactive composition may be at least partially reacted when the coreactive components come together,such as in a mixing volume, just prior to extrusion. Alternatively, the two coreactive components could be premixed before extrusion and treated in a way to arrest the reaction (c.g., arrest curing of the coreactive composition), such as freezing the mixture upon mixing.

[0022] It may be desirable to select the chemistry of each layer of the deposited coreactive composition such that covalent bonds between each successive layer of material are formed. Furthermore, different portions of the article can be printed from different coreactive compositions (e.g., a first coreactive composition printed to form a first portion of the object such as a base portion, an internal structure, etc., and a second coreactive composition printed to form a second portion of the object), and, depending on the chemical reactivity between the different coreactive compositions, covalent bonds might also form between different materials.

[0023] Specifically, an article may be printed so as to have a rigid portion and a flexible portion, a rigid portion and a foam-like portion, a tactile portion and a rigid and / or flexible portion, two portions comprising different densities, one or more conductive portions, one or more thermally / electrically conductive portions, two or more different colors, two or more different rheological profiles, two or more different materials comprising different affinities for water and / or solvent(s), and the like. The article may also be printed such that the coreactive compositions are deposited onto existing articles (e.g., other thermosets and / or thermoplastics, metals, woods, composite materials, ceramics, etc.) resulting in an article comprising both coreactive and non-coreactive compositions.

[0024] Additive manufacturing as described herein may result in an object having greater strength, particularly along the Z (e.g., vertical) axis, as compared to other extruded or printed parts due to the covalent bonding between the printed layers. Strong intralayer and interlayer covalent bonding results in not only stronger parts, but also in more uniform part geometries; that is, less print lines and / or portion differentials. The ability to form, in one process, objects having multiple substrates and / or portions comprising different coreactive or non-coreactive compositions is a further advantage.

[0025] Table A describes suitable coreactive compositions and the coreactive components from which they can be formed. These coreactive compositions can be printed by any of the methods described herein, either alone or in combination, to form three dimensional objects.

[0026] Another advantage of additive manufacturing using coreactive compositions may be that the coreactive compositions can be three dimensionally printed at relatively low viscosity. Therefore, relatively large amounts (e.g., high relative weight percents) of additives and / or fillers can be included with the coreactive components while maintaining a printable viscosity. Both the type and / or the amount of additives can be selected or “tuned” to result in desirable chemical and / or physical properties of the printed article. Coreactive compositions can be tuned with the addition of additives and / or fillers for desired mechanical performance (e.g., strength, elasticity, rigidity, sag resistance, etc.), surface features (e.g., hardness, texturing, smoothness, etc.), chemical resistance (e.g., solvent resistance, etc.), thermal resistance (including fire retardancy, etc.) or conductivity, and / or electrical insulation or conductivity. Coreactive compositions can also be tuned with the addition of one or more catalytic / activator / accelerant additives in any of the coreactive components to result in desirable reaction kinetics, such as rate of reaction.

[0027] Table B describes additives that can be included with any coreactive compositions, such as those described in Table A. The additives can be included in, either, or both of, the first and second coreactive components (e.g., either, or both of the Part A / Part B), depending on the desired chemical and / or physical properties of the resulting object. In this case, Table B describes specific additives and fillers that may be suitable for ambient reactive extrusion-based three-dimensional printing, however, Table B is non-limiting. Therefore, other additives may be included with the coreactive composition(s), such as additives known to those skilled in the coatings, extrusion, and thermoplastic areas.

[0028] Any suitable combination of coreactive composition(s) and optionally additivc(s) / fillcr(s), can be printed by a three-dimensional printing system adapted for mixing and extruding feedstocks. Two or more volumetric metering pumps (e.g., positive displacement pumps, progressive cavity pumps, etc.) may each respectively discharge, in combination or succession, the two coreactive components associated with a coreactive composition (e.g., the first reactive component discharged by the first metering pump and the second coreactive component discharged by the second metering pump into a mixing volume). In some cases, the mixing volume can include mechanical (e.g., driven) mixing features. Upon entering the mixing volume, the first and second coreactive components begin to mix and react, and thereafter, are extruded through an extrusion print nozzle in an at least partially reacted state. Once extruded, the two coreactive components further react and cure, which, as described above, may be under ambient conditions, to form either a thermoset, a thermoplastic material, or combinations thereof.III. 3D Printable Foam Composition from Coreactive Chemistries

[0029] The present disclosure relates to three-dimensional (3D) printable (e.g., additively manufactured) foam compositions comprising an ambiently-cured coreactive chemistry, such as those described in Section II, above. The foam composition may be used to print a 3D object, and result in numerous beneficial mechanical, thermal, and / or acoustic properties, as will described with further detail herein.

[0030] As described previously, additive manufacturing of foam utilizing reactive extrusion is typically limited to including liquids and / or gas blowing agents in the coreactive composition, which result in highly uncontrollable chemical and physical characteristics. For instance, in the case where a polyurethane foam is formed of coreactive components (e.g., an isocyanate and a polyol), a blowing agent (e.g., CO2, water, and / or other reactive compounds that react for form gases such as CFCs), are added to one portion of the coreactive composition (e.g., water added to the polyol), and during mixing, the blowing agent disperses between the two compositions and is extruded as a foam. Alternatively, the blowing agent may be added directly as a gas during mixing.

[0031] These methods pose significant drawbacks. Firstly, the expansion of the foam is highly uncontrollable, dependent on numerous factors, including extrusion and / or ambient temperatures, mixing ratios of the components, reaction rates of each coreactive component, etc., each of which result in a limited ability to control the foams deposition and expansion. Thisresults in foams that over or under expand, leading to poorly formed foam components. Given that many foam-based objects require precise cellular structures (c.g., acoustical foam, targeting a specific porosity; infill materials requiring specific geometry, etc.), the resulting objects fail to meet material and applications standards. Secondly, such blowing agents effect the overall composition of the resulting physical object, resulting in objects containing, among other substances, chlorofluorocarbon (CFC) compounds, which are becoming increasing more regulated and undesirable. Finally, printing of materials that are actively foaming poses significant challenges to the mechanical equipment, many times clogging the extrusion nozzle, causing skipping in the print lines, and / or aggressive spitting of material, all potentially resulting in inconsistent 3D object geometries. Therefore, what is required is a coreactive foam composition that can be printed consistently and controllably.

[0032] The present foam composition may comprise a coreactive composition, an expandable filler, and optionally, one or more additives, each discussed in sections A-C below. The combination of at least the coreactive composition with the expandable filler results in many benefits including controllable foam expansion and controllable printing geometries. Furthermore, as the expandable filler is unreactive with the coreactive composition (as will be described in further detail herein) the reaction rate and kinetics of the coreactive composition are not adversely effected, lowering the complexity of the mechanical system.

[0033] A. Coreactive Composition

[0034] The foam composition may comprise a coreactive composition of any of the coreactive chemistries in Table A, above. The foam may comprise an amount of coreactive composition from 25 wt. %, 35 wt. %, 40 wt. %, or 50 wt. % to 60 wt. %, 70 wt. %, 80 wt. %, or 99 wt. %, or any range using any two of the foregoing values as endpoints, such as 25 wt. % to 99 wt. %, 35 wt. % to 80 wt. %, 40 wt. % to 70 wt. %, or 50 wt. % to 60 wt. %, based on the total weight of the foam composition.

[0035] The coreactive composition may comprise a first coreactive component (A) and a second coreactive component (B), selected from the coreactive chemistries in Table A. The amount of each of the first and second coreactive components in the foam composition may vary based on the coreactive chemistry of the coreactive composition. For a polyurea coreactive composition, the first coreactive component may be present in the foam composition in an amount from 25 wt. %, 30 wt. %, or 35 wt. % to 40 wt. %, 45 wt. %, or 50 wt. %, or any rangeusing any two of the foregoing values as endpoints, such as 25 wt. % to 50 wt. %, 30 wt. % to 45 wt. %, or 35 wt. % to 40 wt. %, based on the total weight of the foam composition. The second coreactive component of the polyurea coreactive composition may be present in the foam composition in an amount from 35 wt. %, 40 wt. %, or 45 wt. % to 50 wt. %, 55 wt. %, or 60 wt. %, or any range using any two of the foregoing values as endpoints, such as 35 wt. % to 60 wt. %, 40 wt. % to 55 wt. %, or 45 wt. % to 50 wt. %, based on the total weight of the foam composition.

[0036] For an Aza-Michael coreactive composition, the first coreactive component may be present in the foam composition in an amount from 15 wt. %, 20 wt. %, or 25 wt. % to 30 wt. %, 35 wt. %, or 40 wt. %, or any range using any two of the foregoing values as endpoints, such as 15 wt. % to 40 wt. %, 20 wt. % to 35 wt. %, or 25 wt. % to 30 wt. %, based on the total weight of the foam composition. The second coreactive component of the Aza-Michael coreactive composition may be present in the foam composition in an amount from 35 wt. %, 40 wt. %, or 45 wt. % to 50 wt. %, 55 wt. %, or 60 wt. %, or any range using any two of the foregoing values as endpoints, such as 35 wt. % to 60 wt. %, 40 wt. % to 55 wt. %, or 45 wt. % to 50 wt. %, based on the total weight of the foam composition.

[0037] For an epoxy amine coreactive composition, the first coreactive component may be present in the foam composition in an amount from 55 wt. %, 60 wt. %, or 65 wt. % to 70 wt. %, 75 wt. %, or 80 wt. %, or any range using any two of the foregoing values as endpoints, such as 55 wt. % to 80 wt. %, 60 wt. % to 75 wt. %, or 65 wt. % to 70 wt. %, based on the total weight of the foam composition. The second coreactive component of the epoxy amine coreactive composition may be present in the foam composition in an amount from 10 wt. %, 15 wt. %, or 20 wt. % to 25 wt. %, 30 wt. %, or 35 wt. %, or any range using any two of the foregoing values as endpoints, such as 10 wt. % to 35 wt. %, 15 wt. % to 30 wt. %, or 20 wt. % to 25 wt. %, based on the total weight of the foam composition.

[0038] For a polyurethane coreactive composition, the first coreactive component may be present in the foam composition in an amount from 35 wt. %, 40 wt. %, or 45 wt. % to 50 wt. %, 55 wt. %, or 60 wt. %, or any range using any two of the foregoing values as endpoints, such as 35 wt. % to 60 wt. %, 40 wt. % to 55 wt. %, or 45 wt. % to 50 wt. %, based on the total weight of the foam composition. The second coreactive component of the polyurethane coreactive composition may be present in the foam composition in an amount from 35 wt. %, 40 wt. %, or45 wt. % to 50 wt. %, 55 wt. %, or 60 wt. %, or any range using any two of the foregoing values as endpoints, such as 35 wt. % to 60 wt. %, 40 wt. % to 55 wt. %, or 45 wt. % to 50 wt. %, based on the total weight of the foam composition.

[0039] For a polysulfide coreactive composition, the first coreactive component may be present in the foam composition in an amount from 1 wt. %, 5 wt. %, or 10 wt. % to 15 wt. %, 20 wt. %, or 25 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 25 wt. %, 5 wt. % to 20 wt. %, or 10 wt. % to 15 wt. %, based on the total weight of the foam composition. The second coreactive component of the polysulfide coreactive composition may be present in the foam composition in an amount from 70 wt. %, 75 wt. %, or 80 wt. % to 85 wt. %, 90 wt. %, or 95 wt. %, or any range using any two of the foregoing values as endpoints, such as 70 wt. % to 95 wt. %, 75 wt. % to 90 wt. %, or 80 wt. % to 85 wt. %, based on the total weight of the foam composition.

[0040] For a polythioether coreactive composition, the first coreactive component may be present in the foam composition in an amount from 1 wt. %, 5 wt. %, or 10 wt. % to 15 wt. %, 20 wt. %, or 25 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 25 wt. %, 5 wt. % to 20 wt. %, or 10 wt. % to 15 wt. %, based on the total weight of the foam composition. The second coreactive component of the polythioether coreactive composition may be present in the foam composition in an amount from 60 wt. %, 65 wt. %, or 70 wt. % to 75 wt. %, 80 wt. %, or 85 wt. %, or any range using any two of the foregoing values as endpoints, such as 60 wt. % to 85 wt. %, 65 wt. % to 80 wt. %, or 70 wt. % to 75 wt. %, based on the total weight of the foam composition.

[0041] For a platinum cured silicone coreactive composition, the first coreactive component may be present in the foam composition in an amount from 70 wt. %, 75 wt. %, or 80 wt. % to 85 wt. %, 90 wt. %, or 95 wt. %, or any range using any two of the foregoing values as endpoints, such as 70 wt. % to 95 wt. %, 75 wt. % to 90 wt. %, or 80 wt. % to 85 wt. %, based on the total weight of the foam composition. The second coreactive component of the platinum cured silicone coreactive composition may be present in the foam composition in an amount from 1 wt. %, 5 wt. %, or 10 wt. % to 15 wt. %, 20 wt. %, or 25 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 25 wt. %, 5 wt. % to 20 wt. %, or 10 wt. % to 15 wt. %, based on the total weight of the foam composition.

[0042] For a condensation cured silicone coreactive composition, the first coreactive component may be present in the foam composition in an amount from 1 wt. %, 5 wt. %, or 10 wt. % to 15 wt. %, 20 wt. %, or 25 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 25 wt. %, 5 wt. % to 20 wt. %, or 10 wt. % to 15 wt. %, based on the total weight of the foam composition. The second coreactive component of the condensation cured silicone coreactive composition may be present in the foam composition in an amount from 70 wt. %, 75 wt. %, or 80 wt. % to 85 wt. %, 90 wt. %, or 95 wt. %, or any range using any two of the foregoing values as endpoints, such as 70 wt. % to 95 wt. %, 75 wt. % to 90 wt. %, or 80 wt. % to 85 wt. %, based on the total weight of the foam composition.

[0043] B. Expandable Filler

[0044] The foam composition may further include an expandable filler. The expandable filler may expand, or increase in volume, when exposed to elevated temperatures, such as during the activation cure discussed below.

[0045] The amount of expandable filler of the foam composition may be adjusted with the inclusion of any one of the additives and / or fillers described in Table B to result in a desired effect, dsa

[0046] The expandable filler may comprise microcapsules, microspheres (e.g., such as Expancel™ microspheres, commercially available from Nouryon), microballoons, and / or glass beads. Suitable expandable fillers may include microspheres, chemical expandable fillers, expandable clay fillers, thermoplastic expandable fillers, and expandable rubber particles. One suitable expandable filler may include microspheres (e.g., micro-balloon, microcapsule, etc.) which enclose a gas that, once heated, expands, increasing the volume of the microsphere.

[0047] The expandable filler may be substantially non-reactive with the coreactive composition and other additives in the foam composition. In this case, the unreactive expandable filler my not interact and / or react with the coreactive composition during curing, and therefore, not effect the overall reaction rate and curing performance of the coreactive composition.

[0048] The expandable filler may comprise filler particles in a variety of sizes and shapes. For instance, the fillers may be hollow substantially spherical (or spherical like) shapes, and containing a preferred blowing agent. The size of the inactivated expandable filler particles may have a D950) particle size from 5 pm, 10 pm, or 15 pm to 20, pm, 30 pm , or 40 pm , or any range using any two of the foregoing values as endpoints, such as 5 pm to 40 pm, 10 pm to30 pm, or 15 m to 20 pm. Once expanded, the expandable filler may expand by up to 600%, drastically increasing the volume of the foam composition.

[0049] Once fully cured, the foam composition may have a targeted and / or desired density, as based upon the inclusion of the expandable filler. For instance, the foam composition comprising the expandable filler, such as Expancel ™, may be 3D printed as the infill element within an open volume, or void, of an object. The printed volume of the foam composition may not completely fill the open volume of the object, but conform with the targeted final geometry (E.g., a base layer of a 3D object). Once printed, the foam composition may be allowed to cure under ambient conditions or an otherwise lower temperature, such as between 20°C and 85 °C, for a given time, creating a cured inactivated foam. After initially curing, the foam comprising the expandable filler may undergo an activation at a higher temperature range, in order to activate the expansion of the expandable filler. For instance, the activation temperature may be between 80°C and 150°C. Once activated, the expandable filler may increase in diameter by 400%, such as from about 10 m to 40 pm, increasing the overall volume of the object printed using the foam composition by up to 2000%. The expanded (activated) foam may now fill a greater portion of the open volume of the object than the foam composition initially filled. The volumetric expansion of the microspheres may be regarded as controllable, in that the expansion rate of the microspheres is temperature dependent and can be controlled as based upon the activation temperature and / or curing time.

[0050] The foam composition may comprise an amount of expandable filler from 6 wt. %, 8 wt. %, 10 wt. %, or 12 wt. % to 14 wt. %, 16 wt. %, 18 wt. %, or 20 wt. %, or any range using any two of the foregoing values as endpoints, such as 6 wt. % to 20 wt. %, 8 wt. % to 18 wt. %, 10 wt. % to 16 wt. %, or 12 wt. % to 14 wt. %, based on the total weight of the foam composition.

[0051] C. Additives

[0052] The foam composition may comprise a variety of fillers. Additives may include rheology modifiers, such as Carbosil TS-720; wetting and dispersing additives, such as Byk 9077; UV stabilizers, such as Cyasorb UV-1164L; amine light stabilizers, such as Tinuyin; catalysts, such as l,8-Diazabicyclo[5.4.0]undec-7-ene, polyether tri-amine; strengthening fillers, such as Wollastonite NY AD 9000; and any other suitable additive for additively manufactured foams.

[0053] The foam composition may comprise a total amount of additive from 0 wt. %, 1 wt. %, or 5 wt. % to 10 wt. %, 15 wt. %, or 20 wt. %, or any range using any two of the foregoing values as endpoints, such as 0 wt. % to 20 wt. %, 1 wt. % to 15 wt. %, or 5 wt. % to 10 wt. %, based on the total weight of the foam composition. The fillers and their amounts may depend on the type of coreactive chemistry of the coreactive composition.

[0054] For instance, a foam composition comprising polyurea coreactive composition may have an amount of a rheology modifier from 1 wt. %, 2 wt. %, or 4 wt. % to 6 wt. %, 8 wt. %, or 10 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 10 wt. %, 2 wt. % to 8 wt. %, or 4 wt. % to 6 wt. %, based on the total weight of the foam composition. The foam composition comprising polyurea may have an amount of a wetting and dispersing additive from 0.1 wt. %, 0.5 wt. %, or 1 wt. % to 3 wt. %, 4 wt. %, or 5 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.1 wt. % to 5 wt. %, 0.5 wt. % to 4 wt. %, or 1 wt. % to 3 wt. %, based on the total weight of the foam composition. The foam composition comprising polyurea may have an amount of a UV light stabilizer from 0.1 wt. %, 0.5 wt. %, or 1 wt. % to 3 wt. %, 4 wt. %, or 5 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.1 wt. % to 5 wt. %, 0.5 wt. % to 4 wt. %, or 1 wt. % to 3 wt. %, based on the total weight of the foam composition. The foam composition comprising polyurea may have an amount of an amine light stabilizer from 0.1 wt. %, 0.5 wt. %, or 1 wt. % to 3 wt. %, 4 wt. %, or 5 wt. %, or any range using any two of the foregoing values as endpoints, such as 0.1 wt. % to 5 wt. %, 0.5 wt. % to 4 wt. %, or 1 wt. % to 3 wt. %, based on the total weight of the foam composition.

[0055] For instance, a foam composition comprising Aza-Michael coreactive composition may have an amount of a rheology modifier from 1 wt. %, 2 wt. %, or 4 wt. % to 6 wt. %, 8 wt. %, or 10 wt. %, or any range using any two of the foregoing values as endpoints, such as 1 wt. % to 10 wt. %, 2 wt. % to 8 wt. %, or 4 wt. % to 6 wt. %, based on the total weight of the foam composition. The foam composition comprising Aza-Michael may have an amount of a catalyst from 5 wt. %, 6 wt. %, or 7 wt. % to 8 wt. %, 9 wt. %, or 10 wt. %, or any range using any two of the foregoing values as endpoints, such as 5 wt. % to 10 wt. %, 6 wt. % to 9 wt. %, or 7 wt. % to 8 wt. %, based on the total weight of the foam composition. The foam composition comprising Aza-Michael may have an amount of a strengthening filler from 5 wt. %, 7 wt. %, or 9 wt. % to 11 wt. %, 13 wt. %, or 15 wt. %, or any range using any two of theforegoing values as endpoints, such as 5 wt. % to 15 wt. %, 7 wt. % to 13 wt. %, or 9 wt. % to 11 wt. %, based on the total weight of the foam composition.

[0056] IV. Printing and Cure Parameters

[0057] The foam composition may be printed using additive manufacturing to create 3D objects, such as sound dampening parts, multi-material prints, weight-saving interior infill for parts, reinforcement and structural fill for parts, and sandwich-type multi-material structures.

[0058] By using additive manufacturing and 3D printing, the flow of the foam composition may be controlled such that specific shapes may be printed. 3D printing the foam composition can allow for complex geometries to be formed by the inactivated foam object.

[0059] For instance, each component of the foam composition may be loaded into an additive manufacturing device and mixed together in a mixing volume. The inactivated foam composition may then be extruded out of a printing nozzle to print the foam composition into a desired geometry. To print the foam composition, a flow rate of 3mL / min may be used with a layer height of 1.0 mm. The travel speed of the foam composition may be 2400 mm / sec.

[0060] Importantly, the foam composition is extruded / printed in an inactivated state, whereas the expandable filler has not yet expanded.

[0061] Thereafter, the foam composition may undergo both curing and an activation. The curing may take an amount of time from 0, 0.5, or 1 , to 1.5, 2, or 3 days, or any range using any two of the foregoing values as endpoints, such as 0 to 3 days, 0.5 to 2 days, or 1 to 1.5 days.Further, the curing may take place at ambient temperatures or slightly elevated temperatures, such as from 20°C, 30°C, or 40°C to 50°C, 60°C, or 79°C, or any range using any two of the foregoing values as endpoints, such as 20°C to 79°C, 30°C to 60°C, or 40°C to 50°C. Curing the foam composition results in an inactivated foam object, as shown in FIG. 1A. Two inactivated foam objects 10, 20 are printed and cured.

[0062] After curing, the inactivated foam object may undergo an activation to expand the expandable filler. The activation may take an amount of time from 10 min., 15 min., or 20 min. to 40 min., 50 min., or 60 min., or any range using any two of the foregoing values as endpoints, such as 10 to 60 min., 15 to 50 min., or 20 to 40 min. Further, the activation may take place at an elevated temperature from 80°C, 110°C, or 120°C to 130°C, 140°C, or 150°C, or any range using any two of the foregoing values as endpoints, such as 80°C to 150°C, 110°C to 140°C, or 120°C to 130°C. Activating the inactivated foam object results in an expanded foam object. As shownin FIG. IB, objects 10, 20 underwent activation at elevated temperatures, resulting in expanded foam objects 12, 22. Expanded foam objects 12, 22 have a greater volume than inactivated foam objects 10, 20.

[0063] By controlling the amount of expandable filler in the foam composition, as well as the temperature and timing of the activation, complex geometries of the inactivated foam object may be maintained in the expanded foam object. This can be particularly helpful when printing the foam composition to fill voids with complex geometries, limited inlet access to the void, and large volume voids that known expandable foam struggles to conform to.

[0064] V. Expansion of Printed Foam

[0065] The expanded foam object may have a volume larger than the volume of the inactivated foam object. The percent volume change from the inactivated foam object to the activated foam object may be from 10%, 50%, or 100% to 500%, 1000%, or 2000%, or any range using any two of the foregoing values as endpoints, such as 10% to 2000%, 50% to 1000%, or 100% to 500%.EXAMPLES

[0066] Aspects of the present disclosure are further illustrated by reference to the following examples. It will be apparent to those skilled in the art that many modifications, both to materials, and methods, may be practiced without departing from the scope of the disclosure.Example 1 ; Polyurea

[0067] A 3D printable 2K polyurea formulation with expandable fillers, additives, and rheology modifiers was 3D printed and then expanded into foam. The amine and the isocyanate components were formulated using the compositions below. The amine-side composition was made from the components in Table 1.Table 1Amine- side Composition1Desmophen NH-1220, aspartic ester di-amine, CAS# 168253-59-6, commercially available from Covestro LLC2Cabosil TS-720, rheology modifier, CAS# 112945-52-5, commercially available from Cabot Corporation3Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron4Jeffamine T5000, polyether tri-amine, CAS# 64852-22-8, commercially available from Huntsman Corporation5HXA CE-425, di-amine, commercially available from Hanson Group LLC6Byk 9077, wetting and dispersing additive, commercially available from B YK7Cyasorb UV-1164L, UV stabilizer, commercially available from Solvay8Tinuvin 292, amine light stabilizer, commercially available from BASF Coip

[0068] From Table 1, the aspartic ester di-amine, polyether tri-amine, di-amine, expandable filler, wetting and dispersing additive, UV light stabilizer, amine light stabilizer, and rheology modifier listed in Table 1 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0069] The isocyanate-side composition was made from the components listed in Table 2.Table 2Isocyanate- side Composition1Desmodur E1361 BA, isocyanate prepolymer based on TDI, polyether, and polyester, CAS# 9057-91-4, commercially available from Covestro2Desmodur N3900, aliphatic polyisocyanate, CAS# 28182-81-2, commercially available from Covestro3Cabosil TS-720, rheology modifier, CAS# 112945-52-5, commercially available from Cabot Corporation

[0070] From Table 2, the prepolymer, aliphatic polyisocyanate, and rheology modifier were weighed and dispersed in a Max 300L Flacktek DAC cup via standard Speedmixer procedure.

[0071] The amine-side and isocyanate- side compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktck SpccdDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The amine and isocyanate compositions were printed at parameters listed in Table 3.Table 3Print Parameters for Expandable ARE Foam

[0072] The completed expandable foam polyurea square print was cured for 2 days at 71 °C. Once cured the polyurea material was placed in an oven at 125°C for 40 minutes to activate the expandable filler. The polyurea sample expanded with an increase in volume up to 850 %.Example 2: Aza-Michael Addition

[0073] A 3D printable 2K Aza-Michael formulation with expandable fillers, additives, and rheology modifiers was 3D printed and then expanded into foam. The amine and the acrylate components were formulated using the compositions below. The amine-side composition was made from the components in Table 4.Table 4Amine- side Composition1Epikure Curing Agent 3381, Cyclo-aliphatic amine adduct, CAS# 285-13-2, commercially available from Westlakepoxy2Cabosil TS-720, rheology modifier, CAS# 112945-52-5, commercially available from Cabot Corporation3Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron4l,8-Diazabicyclo[5.4.0]undec-7-ene, polyether tri-amine, CAS# 6674-22-2, commercially available from Sigma- Aldrich Corporation5Wollastonite NY AD 9000, Calcium Metasilicate, commercially available from Imerys

[0074] From Table 4, cyclo-aliphatic amine adduct, rheology modifier, expandable filler, catalyst and strengthening filler listed in Table 4 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0075] The acrylate-side composition was made from the components listed in Table 5.Table 5Acrylate- side Composition1Miramer SC9610 polyester melamine multifunctional acrylate, commercially available from Miwon Specialty Chemical2Miramer PU2100 aliphatic urethane difunctional acrylate, difunctional acrylate, commercially available from Miwon Specialty Chemical3Cabosil TS-720, rheology modifier, CAS# 112945-52-5, commercially available from Cabot Corporation

[0076] From Table 5, the melamine acrylate, difunctional acrylate, and rheology modifier were weighed and dispersed in a Max 300L Flacktek DAC cup via standard Speedmixer procedure.

[0077] The amine-side and acrylate-side compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The amine and acrylate compositions were printed at parameters listed in Table 6.Table 6Print Parameters for Expandable ARE Foam

[0078] The completed print of an expandable foam acrylate square was cured and activated the expandable filler at 110°C for 20 minutes. The acrylate sample expanded with an increase in volume up to 189 %.Example 3; Epoxy- Amine

[0079] A 3D printable 2K Epoxy Amine formulation with commercial formulation Novaguard was 3D printed and then expanded into foam. The Novaguard A part and B part components were formulated using the compositions below. The epoxy-side composition was made from the components in Table 7.Table 7Novaguard Part A Composition1Novaguard 810 ER A Pack, phenolic epoxy coating, commercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0080] From Table 7, the Commercially available Novaguard 810 ER Part A from PPG Industries and expandable filler listed in Table 7 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0081] The amine-side composition was made from the components listed in Table 8.Table 8Novaguard Part B Composition1Novaguard 810 ER B Pack, amine hardener, commercially available from PPG Industries2Expancel 031 DU 40, expandable tiller, CAS# 75-28-5 commercially available from Sevron

[0082] From Table 8, the commercially available Novaguard 810 ER Part B from PPG Industries and expandable filler listed in Table 8 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0083] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The Novaguard Part A and Part B compositions were printed at parameters listed in Table 9.Table 9Print Parameters for Expandable ARE Foam Novaguard 810 ER

[0084] The completed expandable foam epoxy amine square print was cured and activated expandable filler at 110°C for 20 minutes. The epoxy amine sample expanded with an increase in volume up to 525 %.Example 4; Polyurethane

[0085] A 3D printable 2K polyurethane formulation with commercial formulation Total Seal 6015 was 3D printed and then expanded into foam. The Total Seal 6015 A part and B part components were formulated using the compositions below. The isocyanate-side composition was made from the components in Table 10.Table 10Total Seal 6015 Pail A Composition1Total Seal 6015 A Pack, isocyanate , ccommercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 comercially available from Sevron

[0086] From Table 10, the commercially available Total Seal 6015 Part A from PPG Industries and expandable filler listed in Table 10 above were weighed into a Max 300L FlacktekDAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0087] The polyol-side composition was made from the components listed in Table 11.Table 11Total Seal 6015 Part B Composition1Total Seal 6015 B Pack, polyol, ccommercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0088] From Table 11, the commercially available Total Seal 6015 Part B from PPG Industries and expandable filler listed in Table 1 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0089] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The Total Seal 6015 Part A and Part B compositions were printed at parameters listed in Table 12.Table 12Print Parameters for Expandable ARE Foam Total Seal 6015

[0090] The completed expandable foam polyurethane square print was cured and activated expandable filler at 110°C for 20 minutes. The polyurethane sample expanded with an increase in volume up to 829.9 %.Example 5: Polysulfide

[0091] A 3D printable 2K polysulfide formulation with commercial formulation PR 1440 was 3D printed and then expanded into foam. The PR 1440 A part and B part components were formulated using the compositions below. The A-side composition was made from the components in Table 13.Table 13PR 1440 Part A Composition1PR 1440 A Pack, polysulfide sealant, commercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0092] From Table 13, the commercially available PR 1440 Part A from PPG Industries and expandable filler listed in Table 1 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0093] The B-side composition was made from the components listed in Table 14.Table 14PR 1440 Part B Composition1PR 1440 B Pack, polysulfide sealant, commercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0094] From Table 14, the commercially available PR 1440 Part B from PPG Industries and expandable filler listed in Table 14 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0095] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The PR 1440 Part A and Part B compositions were printed at parameters listed in Table 15.Table 15Print Parameters for Expandable ARE Foam PR 1440

[0096] The completed expandable foam polysulfide square print was cured for 2 days at 71°C. Once cured the polysulfide material was placed in an oven at 110°C for 15 minutes to activate the expandable filler. The polysulfide PR1440 sample expanded with an increase in volume up to 98.6 %.Example 6; Polythioether

[0097] A 3D printable 2K polythioether formulation with commercial formulation PR2001 was 3D printed and then expanded into foam. The PR2001 A part and B part components were formulated using the compositions below. The A-side composition was made from the components in Table 16.Table 16PR2001 Pail A Composition1PR2001 A Pack, polythioether sealant, commercially available from PPG Industries2Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0098] From Table 16, the commercially available PR2001 Part A from PPG Industries and expandable filler listed in Table 16 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0099] The part B-side composition was made from the components listed in Table 17.Table 17PR2001 Part B Composition1 PR2001 B Pack, poly thioether sealant, commercially available from PPG Industries2 Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0100] From Table 17, the commercially available PR2001 Part B from PPG Industries and expandable filler listed in Table 17 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0101] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The PR2001 Part A and Part B compositions were printed at parameters listed in Table 18.Table 18Print Parameters for Expandable ARE Foam PR2001

[0102] The completed expandable foam polythioether square print was cured for 2 days at 71 °C. Once cured the poly thioether material was placed in an oven at 110°C for 15 minutes to activate the expandable filler. The polythioether sample expanded with an increase in volume up to 1503.0 %.Example 7: Platinum Cured Silicone

[0103] A 3D printable 2K platinum addition cured silicone formulation with commercial formulation RTV630 was 3D printed and then expanded into foam. The RTV630 A part and B part components were formulated using the compositions below. The A-side silicone composition was made from the components in Table 19.Table 19RTV630 Part A Composition1 RTV630 A Pack, vinyl silicone mixture, commercially available from Momentive2 Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0104] From Table 19, the commercially available RTV630 Part A from PPG Industries and expandable filler listed in Table 19 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0105] The Part B silicone composition was made from the components listed in Table 20.Table 20RTV630 Part B Composition1 RTV630 B Pack, hydrosiloxane mixture, commercially available from Momentive2 Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0106] From Table 20, the commercially available RTV630 Part B from Momentive and expandable filler listed in Table 20 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0107] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The RTV630 Part A and Pail B compositions were printed at parameters listed in Table 21.Table 21Print Parameters for Expandable ARE Foam RTV630

[0108] The completed expandable foam platinum cured silicone square print was cured for 2 days at 71 °C. Once cured the platinum cured silicone material was placed in an oven at110°C for 15 minutes to activate the expandable filler. The platinum cured silicone sample expanded with an increase in volume up to 13.5 %.Example 8; Condensation Cured Silicone

[0109] A 3D printable 2K moisture cure silicone formulation with commercial formulation PR 1995 was 3D printed and then expanded into foam. The PR 1995 A part and B part components were formulated using the compositions below. The A-side silicone composition was made from the components in Table 22.Table 22PR 1995 Part A Composition1 PR 1995 A Pack, high temperature sealant, commercially available from PPG Industries2 Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0110] From Tabic 22, the commercially available PR 1995 Part A from PPG Industries and expandable filler listed in Table 22 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0111] The B-side silicone composition was made from the components listed in Table 23.Table 23PR 1995 Part B Composition1 PR 1995 B Pack, high temperature sealant, commercially available from PPG Industries2 Expancel 031 DU 40, expandable filler, CAS# 75-28-5 commercially available from Sevron

[0112] From Table 23, the commercially available PR 1995 Part B from PPG Industries and expandable filler listed in Table 23 above were weighed into a Max 300L Flacktek DAC cup. The components were then dispersed into the mixture via typical Speedmixer procedure.

[0113] The Part A and Part B compositions were transferred from their respective DAC cups to 12oz cartridges via Flacktek SpeedDisc which is optimal for 3D printing by reactive extrusion via Viscotec 2K extruders mounted to a 3D printer. The PR 1995 Part A and Part B compositions were printed at parameters listed in Table 24.Table 24Print Parameters for Expandable ARE Foam Condensed Cured Silicone PR 1995

[0114] The completed expandable foam PR 1995 square print was cured for 2 days at 71°C. Once cured the PR 1995 material was placed in an oven at 110°C for 15 minutes to activate the expandable filler. The PR 1995 sample expanded with an increase in volume up to 724 %.Example 9: Expansion Measurements

[0115] Several samples with the chemistries described in Examples 1-8 were prepared to test their expansion properties. The samples and their physical properties are described in Table 25 below.Table 25Physical Properties of ARE Foam Samples

[0116] This expansion is measured by measuring the dimensions (length, width, and thickness) of the parts before and after the expandable filler is activated above 80°C.

[0117] Wherein particular examples of this disclosure have been described above for purposes of illustration, it will be evident to those skilled in the art that numerous variations of the details of the present disclosure may be made without departing from the disclosure as defined in the appended claims. This application is therefore intended to cover any variations, uses, or adaptations of the disclosure using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this disclosure pertains and which fall within the limits of the appended claims.ASPECTS

[0118] Aspect 1 is a method of additively manufacturing an object, comprising: mixing a foam composition comprising: a coreactive composition; and an expandable filler; extruding the foam composition to form a printed foam object; curing the foam object; and activating the foam object to form an expanded foam object.

[0119] Aspect 2 is the method of Aspect 1, wherein curing the foam composition includes curing the foam composition at 20°C to 30°C for 0 days to 3 days.

[0120] Aspect 3 is the method of Aspect 1, wherein curing the foam composition includes curing the foam composition at a temperature between 20°C to 79°C for 0 days to 3 days.

[0121] Aspect 4 is the method of any one of Aspects 1 -3, wherein activating the foam object comprises exposing the foam object to a temperature between 80°C to 150°C for 10 min. to 60 min.

[0122] Aspect 5 is the method of any one of Aspects 1-4, wherein the foam composition comprises: 25-99 wt. % of the coreactive composition; and 6-20 wt. % of the expandable filler.

[0123] Aspect 6 is the method of any one of Aspects 1-5, wherein the foam composition further comprises at least one additive, the at least one additive comprising a rheology modifier, a wetting and dispersing additive, a UV light stabilizer, an amine light stabilizer, a catalyst, and a strengthening filler.

[0124] Aspect 7 is the method of any one of Aspects 1-6, wherein the coreactive composition is one of a polyurea, an Aza-Michael, an epoxy amine, a polyurethane, a polysulfide, a polythioether, a platinum cured silicone, and a condensation cured silicone coreactive composition.

[0125] Aspect 8 is the method of any one of Aspects 1-7, wherein extruding the foam composition further comprises extruding the foam composition at a flow rate of 3 mL / min.

[0126] Aspect 9 is the method of any one of Aspects 1-8, wherein the foam object has a layer height of 1.0 mm.

[0127] Aspect 10 is the method of any one of Aspects 1-9, wherein a percent volume change between the printed foam object to the expanded foam object is between 10% and 2000%.

[0128] Aspect 11 is a printable foam for additive manufacturing, comprising: a coreactive composition; and an expandable filler.

[0129] Aspect 12 is the printable foam of Aspect 11, wherein the coreactive composition comprises a first coreactive component and a second coreactive component; and wherein the first coreactive component and the second coreactive component react and cure under ambient conditions.

[0130] Aspect 13 is the printable foam of either Aspect 11 or Aspect 12, wherein the coreactive composition is at least one of polyurea, Aza-Michael addition, epoxy-amine, polyurethane, polysulfide, polythioether, platinum cured silicone, and condensation cured silicone.

[0131] Aspect 14 is the printable foam of any one of Aspects 11-13, further comprising: 25-99 wt. % of the corcactivc composition; and 6-20 wt. % of the expandable filler.

[0132] Aspect 15 is the printable foam of any one of Aspects 11-14, further comprising at least one additive.

[0133] Aspect 16 is the printable foam of Aspect 15, wherein the at least one additive is one of: a rheology modifier; a wetting and dispersing additive; a UV stabilizer; an amine light stabilizer; a catalyst; and a strengthening filler.

[0134] Aspect 17 is the printable foam of any one of Aspects 11-16, wherein the printable foam cures at temperatures between 20°C and 79°C and expands at temperatures between 80°C and 150°C.

[0135] Aspect 18 is the printable foam of any one of Aspects 11-17, wherein the foam is configured to expand such that the percent volume change from the unexpanded foam to the expanded foam is from 10% to 2000%.

[0136] Aspect 19 is an additively manufactured pail, comprising: a coreactive composition; and an expandable filler.

[0137] Aspect 20 is the additively manufactured pail of Aspect 19, wherein the coreactive composition is at least one of polyurea, Aza-Michael addition, epoxy-amine, polyurethane, polysulfide, polythioether, platinum cured silicone, and condensation cured silicone.

[0138] Aspect 21 is a component additively manufactured according to any one of Aspects 1 through 10.

[0139] Aspect 22 is a method for additively manufacturing a component according to any one of Aspects 11 through 20.

[0140] Aspect 23 is a system for additively manufacturing a component according to of any one of Aspects 11 through 20.

[0141] Aspect 24 is a system of additively manufacturing a component according to the method of any one of Aspects 1 through 10.

Claims

CLAIMSWhat is claimed is:

1. A method of additively manufacturing an object, comprising: mixing a foam composition comprising: a coreactive composition; and an expandable filler; extruding the foam composition to form a printed foam object; curing the foam object; and activating the foam object to form an expanded foam object.

2. The method of claim 1, wherein curing the foam composition includes curing the foam composition at 20°C to 30°C for 0 days to 3 days.

3. The method of claim 1, wherein curing the foam composition includes curing the foam composition at a temperature between 20°C to 79°C for 0 days to 3 days.

4. The method of any one of claims 1-3, wherein activating the foam object comprises exposing the foam object to a temperature between 80°C to 150°C for 10 min. to 60 min.

5. The method of any one of claims 1-4, wherein the foam composition comprises: 25-99 wt. % of the coreactive composition; and6-20 wt. % of the expandable filler.

6. The method of any one of claims 1-5, wherein the foam composition further comprises at least one additive, the at least one additive comprising a rheology modifier, a wetting and dispersing additive, a UV light stabilizer, an amine light stabilizer, a catalyst, and a strengthening filler.

7. The method of any one of claims 1-6, wherein the coreactive composition is one of a polyurea, an Aza-Michael, an epoxy amine, a polyurethane, a poly sulfide, a poly thioether, a platinum cured silicone, and a condensation cured silicone coreactive composition.

8. The method of any one of claims 1-7, wherein extruding the foam composition further comprises extruding the foam composition at a flow rate of 3 mL / min.

9. The method of any one of claims 1-8, wherein the foam object has a layer height of 1.0 mm.

10. The method of any one of claims 1-9, wherein a percent volume change between the printed foam object to the expanded foam object is between 10% and 2000%.

11. A printable foam for additive manufacturing, comprising: a coreactive composition; and an expandable filler.

12. The printable foam of claim 11, wherein the coreactive composition comprises a first coreactive component and a second coreactive component; and wherein the first coreactive component and the second coreactive component react and cure under ambient conditions.

13. The printable foam of either claim 1 1 or claim 12, wherein the coreactive composition is at least one of polyurea, Aza-Michael addition, epoxy-amine, polyurethane, polysulfide, polythioether, platinum cured silicone, and condensation cured silicone.

14. The printable foam of any one of claims 11-13, further comprising:25-99 wt. % of the coreactive composition; and6-20 wt. % of the expandable filler.

15. The printable foam of any one of claims 11-14, further comprising at least one additive.

16. The printable foam of claim 15, wherein the at least one additive is one of: a rheology modifier;a wetting and dispersing additive; a UV stabilizer; an amine light stabilizer; a catalyst; and a strengthening filler.

17. The printable foam of any one of claims 11-16, wherein the printable foam cures at temperatures between 20°C and 79°C and expands at temperatures between 80°C and 150°C.

18. The printable foam of any one of claims 11-17, wherein the foam is configured to expand such that the percent volume change from the unexpanded foam to the expanded foam is from 10% to 2000%.

19. An additively manufactured pail, comprising: a coreactive composition; and an expandable filler.

20. The additively manufactured part of claim 19, wherein the coreactive composition is at least one of polyurea, Aza-Michael addition, epoxy-amine, polyurethane, polysulfide, polythioether, platinum cured silicone, and condensation cured silicone.

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