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Method for building three-dimensional models in extrusion-based additive manufacturing systems using core-shell semi-crystalline consumable filaments

  • US 8,801,990 B2
  • Filed: 09/15/2011
  • Issued: 08/12/2014
  • Est. Priority Date: 09/17/2010
  • Status: Active Grant
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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