Additive manufacturing with polyamide consumable materials
First Claim
1. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
- providing a consumable material comprising a polyamide blend having at least one semi-crystalline polyamide and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the at least one amorphous polyamide constitutes from about 50% by weight to about 85% by weight of the polyamide blend and wherein the consumable material has a solidification temperature and a glass transition temperature, and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and has a relative strength in a conditioned state of at least about 1,600 psi;
heating a chamber of the additive manufacturing system or locally heating a deposition region of the additive manufacturing system to a temperature between the solidification temperature and the glass transition temperature of the consumable material;
feeding the consumable material to a liquefier assembly retained by the additive manufacturing system;
melting the consumable material in the liquefier assembly; and
extruding the molten consumable material from the liquefier assembly as a series of roads in the heated chamber or the locally-heated deposition region to print the three-dimensional part in a layer-by-layer manner.
1 Assignment
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Accused Products
Abstract
A consumable material for use in an additive manufacturing system, the consumable filament comprising a polyamide blend of at least one semi-crystalline polyamide, and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, and a physical geometry configured to be received by the additive manufacturing system for printing a three-dimensional part from the consumable material in a layer-by-layer manner using an additive manufacturing technique. The consumable material is preferably capable of printing three-dimensional parts having good part strengths and ductilities, and low curl.
109 Citations
18 Claims
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1. A method for printing a three-dimensional part with an additive manufacturing system, the method comprising:
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providing a consumable material comprising a polyamide blend having at least one semi-crystalline polyamide and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the at least one amorphous polyamide constitutes from about 50% by weight to about 85% by weight of the polyamide blend and wherein the consumable material has a solidification temperature and a glass transition temperature, and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and has a relative strength in a conditioned state of at least about 1,600 psi; heating a chamber of the additive manufacturing system or locally heating a deposition region of the additive manufacturing system to a temperature between the solidification temperature and the glass transition temperature of the consumable material; feeding the consumable material to a liquefier assembly retained by the additive manufacturing system; melting the consumable material in the liquefier assembly; and extruding the molten consumable material from the liquefier assembly as a series of roads in the heated chamber or the locally-heated deposition region to print the three-dimensional part in a layer-by-layer manner. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A consumable material for use in an additive manufacturing system, the consumable material comprising:
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a polyamide blend comprising; at least one semi-crystalline polyamide; and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the at least one amorphous polyamide constitutes from about 50% by weight to about 85% by weight of the polyamide blend and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and a relative strength in a conditioned state of at least about 1,600 psi; and a physical geometry configured to be received by the additive manufacturing system for printing a three-dimensional part from the consumable material in a layer-by-layer manner using an additive manufacturing technique. - View Dependent Claims (8, 9, 10, 11, 12)
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13. A consumable assembly for use in an extrusion-based additive manufacturing system, the consumable assembly comprising:
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a container portion; a consumable filament at least partially retained by the container portion, the consumable filament comprising; a polyamide blend comprising; at least one semi-crystalline polyamide; and at least one amorphous polyamide that is substantially miscible with the at least one semi-crystalline polyamide, wherein the at least one amorphous polyamide constitutes from about 50% by weight to about 85% by weight of the polyamide blend and wherein the consumable material is capable of printing a three-dimensional part having a curl less than about 0.01 inches pursuant to a Curl Bar Test, and a relative strength in a conditioned state of at least about 1,600 psi; and a filament geometry configured to be received by the extrusion-based additive manufacturing system for printing a three-dimensional part from the consumable filament in a layer-by-layer manner using an additive manufacturing technique. - View Dependent Claims (14, 15, 16, 17, 18)
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Specification