Build materials containing nanofibers for use with extrusion-based layered depositions systems

• US 7,910,041 B1
• Filed: 12/11/2007
• Issued: 03/22/2011
• Est. Priority Date: 11/27/2006
• Status: Active Grant

• Current Assignee: Stratasys Incorporated
• Original Assignee: Stratasys Incorporated
• Inventors: Priedeman, William R. Jr.
• Primary Examiner(s): Tarazano; D. Lawrence
• Assistant Examiner(s): Thompson; Camie S
• Application Number:
  US12/001,403
• Time in Patent Office: 1,197 Days
• Field of Search: None
• US Class Current: 264/319
• 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: B29K 2105/12 of short lengths, e.g. chopped filaments, staple fibres or bristles
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing

Abstract

A method for building a three-dimensional object, the method comprising extruding a build material having a temperature profile between a surface and a central region of the extruded build material in which the surface has a higher temperature than the central region of the build material. The build material comprises a carrier material and nanofibers.

Claims

1. A method for building a three-dimensional object with an extrusion-based layered deposition system, the method comprising:

feeding a build material to an extrusion component of the extrusion-based layered deposition system, the build material comprising a carrier material and nanofibers;

melting the carrier material of the build material in the extrusion component to form a melt comprising the carrier material and the nanofibers, the melt having an axial temperature profile;

extruding the melt from the extrusion component at an extrusion rate ranging from about 800 mics to about 2,500 mics, wherein the extruded melt has a surface and a central region, and further comprises;

a viscosity profile between the surface and the central region based in part on the axial temperature profile, the viscosity profile exhibiting a higher viscosity of the build material adjacent to the surface compared to the central region; and

a concentration profile of the nanofibers between the surface and the central region based on the viscosity profile, wherein the nanofiber concentration profile exhibits a higher concentration of the nanofibers adjacent to the surface compared to the central region; and

depositing the extruded melt in a layer-by-layer manner to build at least a portion of the three-dimensional object.

2. The method of claim 1, wherein extruding the melt from the extrusion component comprises extruding the melt from an extrusion tip of the extrusion component, the extrusion tip having an inner diameter ranging from about 100 micrometers to about 1,000 micrometers.

3. The method of claim 1, further comprising providing the build material to the extrusion-based layered deposition system as a filament.

4. The method of claim 1, wherein the carrier material comprises a thermoplastic material present in the build material at a concentration ranging from about 50.0% by volume to about 99.9% by volume.

5. The method of claim 4, wherein the thermoplastic material is present in the build material at a concentration ranging from about 75.0% by volume to about 95.0% by volume.

6. The method of claim 5, wherein the thermoplastic material is present in the build material at a concentration ranging from about 85.0% by volume to about 90.0% by volume.

7. The method of claim 1, wherein the nanofibers are present in the build material at a concentration ranging from about 50.0% by volume to about 99.9% by volume.

8. The method of claim 7, wherein the nanofibers are present in the build material at a concentration ranging from about 5.0% by volume to about 25.0% by volume.

9. The method of claim 8, wherein the nanofibers are present in the build material at a concentration ranging from about 10.0% by volume to about 15.0% by volume.

10. The method of claim 1, wherein the carrier material comprises a thermoplastic material selected from the group consisting of acrylonitrile-butadiene-styrenes, polycarbonates, polyphenylsulfones, polysulfones, nylons, polystyrenes, polyamides, polyetherimides, polyesters, polyphenylene ethers, polyurethanes, polyetheretherketones, fluoropolymers, and combinations thereof.

11. The method of claim 1, wherein the nanofibers are selected from the group consisting of nanotube fibers, nanowire fibers, and combinations thereof.

12. A method for building a three-dimensional object with an extrusion-based layered deposition system having an extrusion head, the method comprising:

feeding a build material to a liquefier of the extrusion head, the build material comprising a carrier material and nanofibers;

at least partially melting the carrier material in the liquefier to form a melt of the carrier material and the nanofibers, the melt having an axial temperature profile;

generating a viscosity profile between a surface and a central region of the melt based in part on the axial temperature profile, the viscosity profile exhibiting a higher viscosity of the build material adjacent to the surface compared to the central region;

generating a concentration profile of the nanofibers between the surface and the central region based on the viscosity profile, wherein the nanofibers concentration profile exhibits a higher concentration of the nanofibers adjacent to the surface compared to the central region; and

depositing the melt from the extrusion head at a rate ranging from about 800 mics to about 2,500 mics, in a layer-by-layer manner to build at least a portion of the three-dimensional object.

13. The method of claim 12, wherein the carrier material comprises a thermoplastic material present in the build material at a concentration ranging from about 50.0% by volume to about 99.9% by volume.

14. The method of claim 12, wherein the nanofibers are present in the build material at a concentration ranging from about 50.0% by volume to about 99.9% by volume.

15. The method of claim 12, wherein the carrier material comprises a thermoplastic material selected from the group consisting of acrylonitrile-butadiene-styrenes, polycarbonates, polyphenylsulfones, polysulfones, nylons, polystyrenes, polyamides, polyetherimides, polyesters, polyphenylene ethers, polyurethanes, polyetheretherketones, fluoropolymers, and combinations thereof.

16. The method of claim 12, wherein the nanofibers are selected from the group consisting of nanotube fibers, nanowire fibers, and combinations thereof.

17. The method of claim 12, and further comprising providing the build material to the extrusion-based layered deposition system as a filament.

18. The method of claim 12, wherein the deposited melt has a non-cylindrical shape.

19. The method of claim 12, wherein depositing the melt from the extrusion head comprises extruding the melt from an extrusion tip of the extrusion head, the extrusion tip having an inner diameter ranging from about 100 micrometers to about 1,000 micrometers.

20. The method of claim 12, wherein the carrier material comprises a thermoplastic material, and wherein the nanofibers comprise carbon nanotube fibers that are present in the build material at a concentration ranging from about 5.0% by volume to about 25.0% by volume.