Additive manufacturing method for building three-dimensional objects with core-shell arrangements, and three-dimensional objects thereof
First Claim
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1. A three-dimensional object built with an extrusion-based additive manufacturing system, the three-dimensional object comprising:
- a plurality of solidified layers each comprising roads formed from a flowable consumable material that exits an extrusion tip of the extrusion-based additive manufacturing system, wherein the flowable consumable material exiting the extrusion tip comprises a core material and a shell material that is compositionally different from the core material, and wherein the shell material encases the core material to provide an interface between the core material and the shell material; and
wherein at least a portion of the roads of the plurality of solidified layers comprise core regions of the core material and shell regions of the shell material, and wherein the core regions and the shell regions substantially retain cross-sectional profiles corresponding to the interface between the core material and the shell material of the flowable consumable material.
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Abstract
A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.
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Citations
18 Claims
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1. A three-dimensional object built with an extrusion-based additive manufacturing system, the three-dimensional object comprising:
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a plurality of solidified layers each comprising roads formed from a flowable consumable material that exits an extrusion tip of the extrusion-based additive manufacturing system, wherein the flowable consumable material exiting the extrusion tip comprises a core material and a shell material that is compositionally different from the core material, and wherein the shell material encases the core material to provide an interface between the core material and the shell material; and wherein at least a portion of the roads of the plurality of solidified layers comprise core regions of the core material and shell regions of the shell material, and wherein the core regions and the shell regions substantially retain cross-sectional profiles corresponding to the interface between the core material and the shell material of the flowable consumable material. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A three-dimensional object built with an extrusion-based additive manufacturing system, the three-dimensional object comprising:
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a plurality of solidified layers each comprising roads formed from a flowable consumable material that exits an extrusion tip of the extrusion-based additive manufacturing system, wherein the flowable consumable material exiting the extrusion tip comprises a core material and a shell material that is compositionally different from the core material, and wherein the shell material encases the core material to provide an interface between the core material and the shell material; and wherein at least a portion of the roads of the plurality of solidified layers comprise core regions of the core material and shell regions of the shell material, and wherein the core regions and the shell regions are substantially maintained after extrusion into the plurality of solidified layers. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15)
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16. A three-dimensional object built with an extrusion-based additive manufacturing system, the three-dimensional object comprising:
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a plurality of solidified layers each comprising roads formed from a flowable consumable material that exits an extrusion tip of the extrusion-based additive manufacturing system, wherein the flowable consumable material exiting the extrusion tip comprises a core material and a shell material that is different from the core material, and wherein the shell material encases the core material to provide an interface between the core material and the shell material wherein the core material and the shell material are semi-crystalline materials having peak crystallization temperatures that have at least a 2°
C. or greater difference; andwherein at least a portion of the roads of the plurality of solidified layers comprise core regions of the core material and shell regions of the shell material, and wherein the core regions and the shell regions are substantially maintained after extrusion into the plurality of solidified layers. - View Dependent Claims (17, 18)
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Specification