High-precision modeling filament

• US 7,122,246 B2
• Filed: 02/02/2005
• Issued: 10/17/2006
• Est. Priority Date: 09/21/2001
• Status: Expired due to Term

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Priedeman, William R. Jr., Comb, James W., Skubic, Robert L., Batchelder, John Samuel, Leavitt, Paul J.
• Primary Examiner(s): EDWARDS, NEWTON O
• Application Number:
  US11/049,487
• Publication Number:
  US 20050129941A1
• Time in Patent Office: 622 Days
• Field of Search: 428/364, 428/370, 428/401
• US Class Current: 428/364
• CPC Class Codes: B29C 2948/92123 Diameter or circumference
• CPC Class Codes: B29C 2948/92409 Die; Nozzle zone
• CPC Class Codes: B29C 2948/92523 Force; Tension
• CPC Class Codes: B29C 2948/92571 Position, e.g. linear or angular
• CPC Class Codes: B29C 2948/9259 Angular velocity
• CPC Class Codes: B29C 2948/92619 Diameter or circumference
• CPC Class Codes: B29C 2948/92904 Die; Nozzle zone
• CPC Class Codes: B29C 2948/92933 Conveying, transporting or storage of articles
• CPC Class Codes: B29C 2948/92952 Drive section, e.g. gearbox, motor or drive fluids
• CPC Class Codes: B29C 48/05 Filamentary, e.g. strands
• CPC Class Codes: B29C 48/625 characterised by the ratio of the threaded length of the screw to its outside diameter [L/D ratio]
• CPC Class Codes: B29C 48/92 Measuring, controlling or regulating
• CPC Class Codes: B29C 64/106 using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
• CPC Class Codes: B29C 64/118 using filamentary material being melted, e.g. fused deposition modelling [FDM]
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: Y10T 428/2913 Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/298 Physical dimension

Abstract

Disclosed is a modeling filament for use as feedstock in a fused deposition modeling liquifier, and a method for manufacturing the filament. The diameter and standard deviation of the filament are controlled to meet various tolerance requirements of jam resistance, slip resistance, model strength, liquifier overflow prevention and hysteresis-free transient response. Standard deviation of the filament diameter is matched to a filament target diameter. The resulting filament is used to form high-quality models.

Claims

1. A feedstock of solid material for use in an extrusion apparatus, the feedstock comprising:

a filament having a length and a diameter, wherein the length is greater than 20 feet, and wherein the diameter has an average value in the range between 0.069 and 0.074 inches and a standard deviation of less than or equal to 0.0004 inches over the length.

2. The feedstock of solid material of claim 1, wherein the standard deviation of the diameter of the filament is less than or equal to 0.0003 inches over the length.

3. The feedstock of solid material of claim 1, wherein over the length of the filament the average value of the diameter is in the range between 0.071–

0.072 inches and the standard deviation of the diameter is less than or equal to 0.0003 inches.

4. The feedstock of solid material of claim 1, wherein over the length of the filament the average value of the diameter is in the range between 0.072–

0.073 inches and the standard deviation of the diameter is less than or equal to 0.00015 inches.

5. The feedstock of solid material of claim 1, wherein the filament is thermoplastic.

6. A feedstock of solid material for use in an extrusion apparatus, comprising:

a thermoplastic filament having a length and a diameter, wherein the length is greater than 20 feet, and wherein the diameter has an average value and a standard deviation over the length, such that the average value of the diameter of the filament is in the range between 0.069–

0.074 inches and the standard deviation is less than or equal to the product of the average value of the diameter multiplied by 0.007.

7. The feedstock of solid material of claim 6, wherein the standard deviation of the diameter of the filament is less than or equal to 0.0004 inches over the length.