PES/PPS 3D Printing Feedstock for High-Temp Composite Tooling
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Solution Overview
Problem
Current additive manufacturing materials lack high heat resistance, low coefficient of thermal expansion, and chemical resistance, making them unsuitable for applications requiring high temperature and chemical durability, such as aerospace composite layup manufacturing.
Innovation Solution
A feedstock material blend of polyethersulfone (PES) and polyphenylene sulfide (PPS) with a glass transition temperature of 190°C or greater and a coefficient of thermal expansion less than 30 μm/(m·°C), which can be processed in additive manufacturing systems to produce parts with enhanced heat resistance and chemical robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional additive manufacturing materials are used, then ease of manufacture is maintained, but heat resistance and chemical resistance are insufficient
Solution Approach 1:
The patent applies composite materials by blending polyethersulfone (PES) and polyphenylene sulfide (PPS) in specific weight ratios (PES: 30-70 wt%, PPS: 70-30 wt%). This composite approach combines the high heat resistance of PES (Tg ≥ 190°C) with the chemical resistance of PPS, creating a feedstock that simultaneously achieves both properties while remaining processable in standard additive manufacturing systems.
2Reliability
If metal molds are used for composite layup manufacturing, then heat resistance and chemical resistance are achieved, but cost and complexity increase
Solution Approach 1:
The patent applies the copying principle by creating polymer-based tooling inserts that replicate the functional properties of metal molds. The PES/PPS composite feedstock produces printed parts with sufficient heat resistance (Tg ≥ 190°C) and chemical resistance to withstand composite layup manufacturing conditions, providing a lightweight, cost-effective alternative to traditional metal molds while maintaining the necessary reliability.
3Temperature
If high temperature resistant materials are used, then heat resistance is improved, but coefficient of thermal expansion increases
Solution Approach 1:
The patent applies parameter changes by carefully selecting and optimizing the weight ratio composition of PES and PPS in the feedstock. This compositional parameter adjustment allows the material to achieve a balanced performance where the glass transition temperature remains ≥ 190°C for heat resistance, while the coefficient of thermal expansion is controlled within an acceptable range for manufacturing precision in composite layup applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The PES/PPS blend enables the production of 3D parts that withstand high temperatures and chemical exposure, reducing the need for expensive metal molds and improving the durability and reusability of tooling inserts in composite layup manufacturing.
Implementation Method 1
A consumable material includes a polymeric matrix having polyethersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable processing in the additive manufacturing system and having a Tg that is about 190° C. or greater
Implementation Method 2
having a Tg that is about 190° C. or greater and a coefficient of thermal expansion is less than about 23 μm/(m ° C.) to about 29 23 μm/(m ° C.)
Data Source
AI summary
A consumable material configured for use in an additive manufacturing system includes a polymeric matrix having polyetherersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable for processing in the additive manufacturing system and having a Tg that is about 190° C. or greater and a coefficient of thermal expansion of less than about 30 μm/(m·° C.). The consumable material is suitable for use in 3D printing of composite mold tools.