Method for building three-dimensional models in extrusion-based additive manufacturing systems using core-shell semi-crystalline consumable filaments
First Claim
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1. A method for building a three-dimensional object with an additive manufacturing system having a heated build chamber and an extrusion head, the method comprising:
- feeding a consumable filament to the extrusion head, the consumable filament comprising a longitudinal length, a core portion extending along the longitudinal length, and a shell portion extending along the longitudinal length and substantially encasing the core portion, wherein the core portion compositionally comprises a first semi-crystalline polymeric material, and wherein the shell portion compositionally comprises a second semi-crystalline polymeric material having a peak crystallization temperature that is greater than a peak crystallization temperature of the first semi-crystalline polymeric material;
melting the fed consumable filament in the extrusion head to form a molten material;
depositing the molten material in the heated build chamber as an extruded road that defines at least a portion of a layer of the three-dimensional object, wherein the extruded road comprises a core region of the first semi-crystalline polymeric material, and a shell region of the second semi-crystalline polymeric material;
crystallizing at least a portion of the second semi-crystalline polymeric material of the shell region prior to formation of a subsequent layer of the three-dimensional object; and
crystallizing at least a portion of the first semi-crystalline polymeric material of the core region after crystallizing the portion of the second semi-crystalline polymeric material of the shell region.
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Abstract
A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a first portion of a first semi-crystalline polymeric material, and a second portion of a second semi-crystalline polymeric material, and where the second semi-crystalline polymeric material has a crystallization temperature that is greater than a crystallization temperature of the first semi-crystalline polymeric material.
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Citations
20 Claims
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1. A method for building a three-dimensional object with an additive manufacturing system having a heated build chamber and an extrusion head, the method comprising:
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feeding a consumable filament to the extrusion head, the consumable filament comprising a longitudinal length, a core portion extending along the longitudinal length, and a shell portion extending along the longitudinal length and substantially encasing the core portion, wherein the core portion compositionally comprises a first semi-crystalline polymeric material, and wherein the shell portion compositionally comprises a second semi-crystalline polymeric material having a peak crystallization temperature that is greater than a peak crystallization temperature of the first semi-crystalline polymeric material; melting the fed consumable filament in the extrusion head to form a molten material; depositing the molten material in the heated build chamber as an extruded road that defines at least a portion of a layer of the three-dimensional object, wherein the extruded road comprises a core region of the first semi-crystalline polymeric material, and a shell region of the second semi-crystalline polymeric material; crystallizing at least a portion of the second semi-crystalline polymeric material of the shell region prior to formation of a subsequent layer of the three-dimensional object; and crystallizing at least a portion of the first semi-crystalline polymeric material of the core region after crystallizing the portion of the second semi-crystalline polymeric material of the shell region. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A method for building a three-dimensional object with an additive manufacturing system having a heated build chamber and an extrusion head, the method comprising:
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feeding a consumable filament to the extrusion head, the consumable filament comprising; a longitudinal length; a core portion extending along the longitudinal length, wherein the core portion compositionally comprises a first semi-crystalline polymeric material having a first peak crystallization temperature; and a shell portion extending along the longitudinal length and substantially encasing the core portion, wherein the shell portion compositionally comprises a second semi-crystalline polymeric material having a second peak crystallization temperature that is different from the first peak crystallization temperature of the first semi-crystalline polymeric material; melting the fed consumable filament in the extrusion head to form a molten material; depositing the molten material in the heated build chamber as an extruded road of a layer of the three-dimensional object, wherein the extruded road comprises a core region of the first semi-crystalline polymeric material, and a shell region of the second semi-crystalline polymeric material; and begin crystallizing the first semi-crystalline polymeric material of the core region and the second semi-crystalline polymeric material of the shell region at different times. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A method for building a three-dimensional object with an additive manufacturing system having a heated build chamber and an extrusion head, the method comprising:
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feeding a consumable filament to the extrusion head, the consumable filament comprising; a longitudinal length; a core portion extending along the longitudinal length, wherein the core portion compositionally comprises a first polyamide material having a first peak crystallization temperature; and a shell portion extending along the longitudinal length and substantially encasing the core portion, wherein the shell portion compositionally comprises a second polyamide material having a second peak crystallization temperature that is greater than the first peak crystallization temperature of the first polyamide material by at least about 10°
C.;melting the fed consumable filament in the extrusion head to form a molten material; depositing the molten material in the heated build chamber to form a series of extruded roads for a layer of the three-dimensional object, wherein at least a portion of the extruded roads each comprise a core region of the first polyamide material and a shell region of the second polyamide material; and maintaining an environment within the heated build chamber at one or more temperatures that are about equal to, or are within a range of about 20°
C. above or below, the second peak crystallization temperature of the second polyamide material. - View Dependent Claims (18, 19, 20)
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Specification