High-temperature soluble support material for additive manufacturing
First Claim
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1. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
- printing the three-dimensional part with a part material with a glass transition temperature greater than 160°
C., and a support structure with a support material wherein the glass transition temperature of the support material is higher than about 150°
C. and within about 10°
C. of the glass transition temperature of the part material, the melt processing temperature is greater than about 220°
C. and wherein the support material comprises a thermoplastic copolymer comprising carboxylic acid groups wherein a portion of the carboxylic acid groups are neutralized to form carboxylic acid salt groups wherein the amount of carboxylic acid salt groups in the thermoplastic copolymer of the support material is controlled to control the glass transition temperature of the support material.
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Abstract
A support material for use in an additive manufacturing system, which includes a thermoplastic copolymer polymerized from monomers comprising acid-functional monomers having carboxylic acid groups, and one or more non-acid-functional monomers, where a portion of the carboxylic acid groups are neutralized with a base having an alkali metal cation. The thermoplastic copolymer has a high glass transition temperature and melt processing temperature, and is thermally stable at its melt processing temperature. The neutralized thermoplastic copolymer is soluble in an alkaline aqueous solution.
36 Citations
18 Claims
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1. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
printing the three-dimensional part with a part material with a glass transition temperature greater than 160°
C., and a support structure with a support material wherein the glass transition temperature of the support material is higher than about 150°
C. and within about 10°
C. of the glass transition temperature of the part material, the melt processing temperature is greater than about 220°
C. and wherein the support material comprises a thermoplastic copolymer comprising carboxylic acid groups wherein a portion of the carboxylic acid groups are neutralized to form carboxylic acid salt groups wherein the amount of carboxylic acid salt groups in the thermoplastic copolymer of the support material is controlled to control the glass transition temperature of the support material.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method for printing a three-dimensional part with an extrusion-based additive manufacturing system, the method comprising:
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printing the three-dimensional part by extruding a part material in a plurality of layers comprising a plurality of roads, wherein the part material has a glass transition temperature greater than about 160°
C., andprinting a support structure by extruding a support material in a plurality of layers, wherein the support structure provides support for the three-dimensional part as the part is being printed, wherein the glass transition temperature of the support material is higher than about 150°
C., the melt processing temperature is greater than about 220°
C. and wherein the support material comprises a thermoplastic copolymer comprising carboxylic acid groups wherein a portion of the carboxylic acid groups are neutralized to form carboxylic acid salt groups, wherein a concentration of carboxylic acid salt groups is utilized to control the glass transition temperature of the support material. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18)
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Specification