Method for building three-dimensional objects in extrusion-based additive manufacturing systems using core-shell consumable filaments
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-033/52
B29C-067/00
B29C-047/02
B29C-047/04
D01F-008/04
B29C-047/00
B29C-047/06
B32B-003/26
D01F-008/12
B29C-047/92
출원번호
US-0419669
(2012-03-14)
등록번호
US-8920697
(2014-12-30)
발명자
/ 주소
Mikulak, James K.
Deckard, Carl R.
Zinniel, Robert L.
출원인 / 주소
Stratasys, Inc.
대리인 / 주소
Morrison, Brian R.
인용정보
피인용 횟수 :
25인용 특허 :
64
초록▼
A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material,
A consumable filament for use in an extrusion-based additive manufacturing system, where the consumable filament comprises a core portion of a first thermoplastic material, and a shell portion of a second thermoplastic material that is compositionally different from the first thermoplastic material, where the consumable filament is configured to be melted and extruded to form roads of a plurality of solidified layers of a three-dimensional object, and where the roads at least partially retain cross-sectional profiles corresponding to the core portion and the shell portion of the consumable filament.
대표청구항▼
1. A method for building a three-dimensional object with an additive manufacturing system having 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 le
1. A method for building a three-dimensional object with an additive manufacturing system having 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 thermoplastic material, and wherein the shell portion compositionally comprises a second thermoplastic material that is different from the first thermoplastic material;melting the fed consumable filament in the extrusion head to form molten material;depositing the molten material 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 thermoplastic material, and a shell region of the second thermoplastic polymeric material; andsolidifying the extruded road. 2. The method of claim 1, wherein the first thermoplastic material is a first semi-crystalline polymeric material having a first peak crystallization temperature, and wherein the second thermoplastic material is a second semi-crystalline polymeric material having a second peak crystallization temperature that is greater than the first peak crystallization temperature. 3. The method of claim 2, wherein the additive manufacturing system includes a heated build chamber, and wherein the method further comprises 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 10° C. above or below, the peak crystallization temperature of the second semi-crystalline polymeric material. 4. The method of claim 1, wherein the consumable filament is a support material consumable filament and the three-dimensional object is a support structure for a three-dimensional model, and wherein the method further comprises: building a layer of the three-dimensional model with the additive manufacturing system, wherein the layer of the three-dimensional model is supported by the solidified layer of the support structure; andremoving the support structure from the three-dimensional model. 5. The method of claim 4, wherein the second thermoplastic material is at least partially soluble in an aqueous solution, and wherein removing the support structure from the three-dimensional model comprises at least partially dissolving the second thermoplastic material in the aqueous solution. 6. The method of claim 4, wherein the second thermoplastic material of the shell portion comprises a colorant, and wherein the shell of the extruded road also includes the colorant. 7. The method of claim 1, wherein the consumable filament comprises a cylindrical geometry along the longitudinal length. 8. The method of claim 1, wherein the consumable filament has an average cross-sectional area ranging from about 0.5 square millimeters to about 8 square millimeters. 9. A method for building a three-dimensional model and associated support structure with an additive manufacturing system retaining 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, wherein the core portion compositionally comprises a first thermoplastic material; anda shell portion extending along the longitudinal length and substantially encasing the core portion, wherein the shell portion compositionally comprises a second thermoplastic material that is different from the first thermoplastic material, and wherein the second thermoplastic material is soluble in an aqueous liquid;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 support structure, wherein at least a portion of the extruded roads each comprise a core region of the first thermoplastic material and a shell region of the second thermoplastic material;at least partially solidifying the layer; andbuilding a layer of the three-dimensional model from a modeling material with the additive manufacturing system, wherein the layer of the three-dimensional model is supported by the at least partially solidified layer of the support structure. 10. The method of claim 9, wherein the first thermoplastic material of the core portion has a creep relaxation temperature that is within about 20° C. of a creep relaxation temperature of the modeling material. 11. The method of claim 10, wherein the creep relaxation temperature of the first thermoplastic material is within about 10° C. of the creep relaxation temperature of the modeling material. 12. The method of claim 11, wherein the creep relaxation temperature of the first thermoplastic material is within about 5° C. of the creep relaxation temperature of the modeling material. 13. The method of claim 9, wherein the aqueous liquid that the second thermoplastic material is soluble in comprises an alkaline aqueous solution. 14. The method of claim 9, wherein the first thermoplastic material of the core portion has a tensile strength that is higher than a tensile strength of the second thermoplastic material of the shell portion. 15. The method of claim 9, wherein the first thermoplastic material of the core portion is substantially the same as the modeling material. 16. The method of claim 9, wherein the additive manufacturing system includes a heated build chamber, and wherein the method further comprises maintaining an environment within the heated build chamber at one or more temperatures that are between about a solidification temperature of the modeling material and a creep relaxation temperature of the modeling material. 17. The method of claim 9, wherein the core portion of the consumable filament has an average cross-sectional area that is greater than an average cross-sectional area of the shell portion. 18. The method of claim 9, wherein the consumable filament comprises a cylindrical geometry along the longitudinal length. 19. The method of claim 9, wherein the first thermoplastic material of the core portion is not soluble in the aqueous liquid. 20. The method of claim 9, and further comprising exposing the support structure to the aqueous liquid to remove the support structure from the three-dimensional model.
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