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WO2016090164A1 - Filament amélioré pour modélisation par dépôt en fusion - Google Patents

Filament amélioré pour modélisation par dépôt en fusion Download PDF

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Publication number
WO2016090164A1
WO2016090164A1 PCT/US2015/063788 US2015063788W WO2016090164A1 WO 2016090164 A1 WO2016090164 A1 WO 2016090164A1 US 2015063788 W US2015063788 W US 2015063788W WO 2016090164 A1 WO2016090164 A1 WO 2016090164A1
Authority
WO
WIPO (PCT)
Prior art keywords
filament
selecting
modulus
young
core
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2015/063788
Other languages
English (en)
Inventor
Stephen F. HESTON
Anna TOTARO
Sunil Ramachandra
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fenner US Inc
Original Assignee
Fenner US Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fenner US Inc filed Critical Fenner US Inc
Publication of WO2016090164A1 publication Critical patent/WO2016090164A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B29C64/118—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material using filamentary material being melted, e.g. fused deposition modelling [FDM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/106—Processes of additive manufacturing using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/02—Small extruding apparatus, e.g. handheld, toy or laboratory extruders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/288—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules
    • B29C48/2888—Feeding the extrusion material to the extruder in solid form, e.g. powder or granules in thread form or in strip form, e.g. rubber strips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/86—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling at the nozzle zone
    • B29C48/865—Heating

Definitions

  • the present invention relates to the field of additive manufacturing
  • fused deposition modeling or fused filament fabrication. More specifically, the present invention relates to an additive manufacturing technology using low durometer materials having improved characteristics for feeding the materials.
  • FFF fused deposition modeling or fused filament fabrication
  • ABS acrylonitrile butadiene styrene
  • PLA polylactic acid
  • materials such as polyurethanes, silicones, and certain nylon compositions generally provide a broader range of mechanical properties, such as reduced modulus, higher elasticity, and reduced brittleness.
  • mechanical properties such as reduced modulus, higher elasticity, and reduced brittleness.
  • the elasticity and reduced stiffness of these materials cause difficulties in many FFF machines. For this reason, despite the advantages for the resulting product, these materials are not yet widely used in FFF machines.
  • the present invention provides low durometer elastomer materials that work efficiently with known additive manufacturing machines, such as FFF machines.
  • the present invention provides a filament for use with an additive manufacturing machine.
  • the filament may be formed of multiple materials.
  • the filament may comprise an outer jacket formed around an inner core.
  • the inner core may be a more flexible material, while the outer jacket may be more rigid.
  • the outer surface of the filament may have a reduced tackiness to improve the ability to feed the filament through the FFF machine.
  • the filament may have a core of low durometer thermoplastic material within a coating formed of a higher durometer material.
  • the outer jacket and the inner core may be formed from materials having similar glass transition temperatures.
  • the present invention comprises a method of using a thermoplastic filament having a core formed of a first material and a jacket surrounding the core formed of a second material.
  • the second material may be harder than the first material.
  • the second material may be more rigid than the first material.
  • the first and second materials may have similar glass transition temperatures.
  • the method comprises the steps of feeding the filament into a nozzle, melting the core and jacket of the filament, and selectively controlling the position of the nozzle relative to a platform to deposit a plurality of layers of melted materials to produce a three-dimensional item.
  • the present invention provides a system for
  • the system includes an elongated filament comprising a central core of a first material and an outer coating formed of a second material.
  • the second material may be harder than the first material.
  • the second material may be more rigid than the first material.
  • the first and second materials may have similar glass transition temperatures.
  • the system may include a nozzle, a feeder for feeding the filament to the nozzle and a heating element for melting the filament into a melted material.
  • a controller controls the position of the nozzle to control the configuration of the layer of melted material deposited by the nozzle. Specifically, the controller may control the operation of the feeder and the position of the nozzle to build a series of layers of melted material to form a three-dimensional object.
  • Fig. 1 is a side view of a system for creating three-dimensional objects.
  • FIG. 2 is an enlarged fragmentary view of an extrusion head of the system illustrated in Fig. 1 ;
  • Fig. 3 is a diagram illustrating stress/strain curves of various filament
  • Fig. 4 is an enlarged cross-section view of a filament illustrated in the
  • a system for creating three- dimensional objects by depositing multiple layers of material is designated generally 10.
  • the system includes a head 20 for selectively depositing melted material 85 onto a support element, such as a planar platform or other stage (not shown).
  • a length of feedstock 80 is fed to the head 20, which melts the feedstock.
  • the melted material 85 is then deposited in a series of layers to build the object as discussed further below.
  • the system 10 can be any of a variety of additive manufacturing systems.
  • the system 10 may include a controller for controlling the operation of the head 20 to form an object based on an electronic model of the object.
  • the electronic model may break the object down into a series of layers.
  • the controller controls the operation of the head to selectively deposit material in accordance with the series of layers that form the electronic model.
  • the controller may comprise a computer or other microprocessor controlled device that controls the operation of actuators, such as one or more motors that drive the head 20 along two axes in a plane. In this way, the controller controls the position of the head 20 to control where each layer of material is deposited onto a platform or table. By depositing sequential layers of material the system progressively builds the object from numerous layers of deposited material.
  • the system can be configured to move the platform relative to the head 20. In either instance, the system controls the position of the head relative to the platform.
  • the system 10 may be one of a variety of additive manufacturing systems, in the present instance the system is one that includes an extrusion head for extruding the material that forms the object.
  • the system may be a fused deposition modeling device or fused filament fabrication device, such as one or several systems commonly referred to as a 3-D printing device that extrude thermoplastics and other materials.
  • the head is an extrusion head 20 having an input for receiving feedstock 80 that is extruded through a nozzle 30.
  • a feeder 50 positively engages the feedstock to drive the feedstock toward the nozzle 30 in response to signals received from the controller to control the discharge of extruded material from the extrusion head 20.
  • the feeder 50 includes a drive wheel 52 and an opposing idler wheel 54.
  • the idler wheel 54 is mounted on a pivot arm 55 that pivots around a pivot axis 56.
  • a biasing element 58 biases the arm 55 to bias the idler wheel 54 toward the drive wheel 52.
  • the drive wheel 52 and idler wheel 54 form a nip to positively engage the feedstock 80.
  • the drive and idler wheels 52, 54 are rotatable wheels so that the wheels rotate as the feedstock is driven through the nip.
  • the drive wheel 52 positively engages the feedstock to drive the feedstock forwardly.
  • the drive wheel may include a plurality of engagement teeth spaced around the circumference of the drive wheel as shown in Fig. 2.
  • the engagement teeth have edges that dig into or bite the feedstock so that rotating the drive wheel drives the material forwardly toward the nozzle 30.
  • the drive wheel 52 may have a different mechanism for engaging the feedstock.
  • the drive wheel may have a high-friction surface to frictionally engage the feedstock.
  • Operation of the drive wheel 52 is controlled by a positional controller.
  • a motor 60 such as a stepper motor selectively drives the drive wheel 52.
  • the motor 60 receives signals from a controller, such as the central controller controlling operation of the system. In this way, the motor 60 selectively drives the drive wheel 52 to control the feeding of the feedstock to thereby control the flow of melted material exiting the nozzle 30.
  • the feeder 50 drives the feedstock 80 through a barrel that extends to the nozzle 30.
  • the nozzle 30 includes a discharge orifice 32 through which the extruded material 85 exits the extrusion head 20.
  • a heating element 35 at the nozzle is operable to heat the feedstock 80 to an elevated temperature above ambient temperature so the material can be extruded through the nozzle.
  • a heat sink 40 is operable to limit the transfer of heat to the feedstock before the feedstock enters the nozzle 30 so that the feedstock does not start to melt before entering the nozzle.
  • the heatsink also limits of transfer of heat from the nozzle to other components of the extrusion head 20.
  • the filament 80 comprises an elongated element, such as a filament.
  • the filament 80 may be formed into a variety of shapes, however in the present instance the filament is a substantially cylindrical solid filament. A variety of diameters may be used depending on various factors such as the material from which the filament is formed. In the present instance, the filament 80 is approximately 2 mm in diameter.
  • the filament 80 may be wound onto a spool 90 to provide a substantially constant supply of material to the extrusion head 20.
  • the spool may be any of a variety of configurations.
  • the spool may include a central hub or axle around which the material is wound.
  • the hub may be cylindrically shaped or it may comprise a shaped having a non-circular cross-section.
  • the spool may include flanges that project radially outwardly away from the hub.
  • the flanges may be circular as shown in Fig. 1 .
  • the flanges may be spaced apart from one another so that the flanges form sidewalls. In this way, the filament may be wound around the central hub between the flanges.
  • the flanges may form end walls to protect the filament wound around the hub.
  • the feeder 50 drives the filament forwardly toward the nozzle 30, the feeder pulls the filament from the spool.
  • the filament extends through a hollow feed tube 70 that guides the filament as the filament extends from the spool 90 to the extrusion head 20.
  • the filament may be formed of a variety of materials, however, in the present instance, the filament 80 comprises a core 84 of a first material surrounded by a coating or jacket 82 of a second.
  • the core 84 may be formed of a low durometer material, having one or more of the following materials: silicone, rubber, nylon and/or thermoplastic, such as polyurethane.
  • the core material may be primarily formed from a material having a durometer of less than approximately 50 Shore D and greater than approximately 60 Shore A.
  • the durometer of the core material may be less than 90 on the Shore A scale and in the present instance is 85 on the Shore A scale.
  • Such low durometer materials tend to have tacky surfaces so that the materials have a generally high coefficient of friction relative to materials such as ABS and PLA.
  • the filament 80 is coated or jacketed by a layer of second material 82 that may have one or more characteristics that are different than the first material from which the core is formed.
  • the second material may be more rigid than the first material.
  • the second material may be harder than the first material.
  • the second material may have greater tensile strength.
  • the second material may have greater tensile strength.
  • the second material may have greater tensile strength.
  • the second material may have a lower coefficient of friction than the core material. Additionally, the second material may have a glass transition temperature that is similar to the glass transition temperature of the first material.
  • the jacket may be formed of a more rigid material so that the jacket 82 increases the axial rigidity of the filament to reduce the likelihood that the filament will buckle during feeding of the filament to the extrusion head 50.
  • the jacket may have a lower coefficient of friction than the core material to limit the pull force necessary to draw the filament from the spool.
  • the thickness of the jacket is substantially uniform along the length of the filament so that the cross-section of the filament is substantially uniform along the length of the filament.
  • the jacket 82 may be formed of a variety of thermoplastic polymers, including, but not limited to acrylonitrile butadiene styrene (“ABS”), polylactic acid (“PLA”), polyvinyl alcohol (“PVA”), nylon, polystyrene, and polycarbonate.
  • ABS acrylonitrile butadiene styrene
  • PLA polylactic acid
  • PVA polyvinyl alcohol
  • the jacket material is selected to provide a columnar support element, increasing the rigidity of the filament.
  • the jacket thickness may vary depending on the thickness of the filament and the materials used. In the present instance, the jacket thickness is minimized to reduce the percentage that the jacket forms of the overall filament material, while still providing the desired axial rigidity.
  • the thickness of the jacket may vary from 0.025 mm to 0.25 mm, so that the coating is between approximately 5% and 50% of the overall composition of the filament.
  • the thickness of the jacket is between 0.05 mm and 0.2 mm, so that the coating is between approximately 1 1 % and 40% of the overall composition of the filament. More specifically, the thickness of the jacket may be between 0.1 0 mm and 0.15 mm. In particular, the thickness of the jacket may be approximately 0.130 mm.
  • the filament 80 is a composite filament formed of more than one layer.
  • the inner core 84 may be formed of a relatively soft material, such as a polyurethane having a durometer of less than approximately 50 Shore D.
  • the durometer of the core material may be greater than approximately 60 and less than 90 on the Shore A scale and in the present instance is between 80 and 90 on the Shore A scale.
  • the inner core is surrounded by a jacket formed of a material that is harder that the core material.
  • the jacket 82 may be formed of PLA or ABS having a hardness of over 40 Shore D/90 Shore A.
  • the jacket material 82 may be formed of material having a hardness of over 50 Shore D/100 Shore A.
  • the jacket 82 may be formed of a material having a different solubility than the material forming the core.
  • the jacket 82 may be formed from polyvinyl alcohol (PVA) that is a water-soluble synthetic polymer and the core may be formed of thermoplastic polyurethane, which is not soluble in water.
  • PVA polyvinyl alcohol
  • the jacket material is soluble in water and the core material is insoluble in water.
  • solvents other than water may be used. In such applications, the jacket material is soluble in the in the solvent, while the core material is not soluble in the solvent in which the jacket material is soluble.
  • the filament may comprise an inner core formed of a first material and an outer jacket formed of a first material.
  • the first material may be a generally flexible and/or resilient material, while the second material may be a more rigid material to provide increased columnar strength.
  • the first material may have a Young's modulus that is significantly lower than the Young's modulus of the second material.
  • the Young's modulus of the second material may more than twice the Young's modulus of the first material. More specifically, the Young's modulus of the second material may be more than five times the Young's modulus of the first material. Further still, the Young's modulus of the second material may be more than ten times the Young's modulus of the first material.
  • the resulting filament has a rigidity that is stiffer than the first material, but not as stiff as the second material.
  • the composite filament may have a Young's modulus that is at least twice as great as the Young's modulus of the first material, but is less than the Young's modulus of the second material. More specifically, the Young's modulus of the composite filament may have a Young's modulus that is more than five times the Young's modulus of the first material, but is less than the Young's modulus of the second material.
  • the Young's modulus of the composite filament is at least approximately 40% less than the Young's modulus of the second material.
  • the Young's modulus of the composite filament may be 50% less than the Young's modulus of the second material.
  • the Young's modulus of the composite filament may be less than 50% of the Young's modulus of the second material.
  • the first material may have an ultimate tensile strength (i.e. the maximum stress the material can withstand before breaking) that is less than the ultimate tensile strength of the second material. More specifically, the ultimate tensile strength of the second material may be at least twice the ultimate tensile strength of the first material.
  • the ultimate tensile strength of the second material may be at least five times the ultimate tensile strength of the first material.
  • the ultimate tensile strength of the second material may be ten times the ultimate tensile strength of the first material.
  • the ultimate tensile strength of the second material may be between two and ten times the ultimate tensile strength of the first material.
  • the ultimate tensile strength of the second material may be between five and ten times the ultimate tensile strength of the first material. In this way, the ultimate tensile strength of the composite material is greater than the ultimate tensile strength of the first material and less than the ultimate tensile strength of the second material.
  • the ultimate tensile strength of the composite filament may be at least twice the ultimate tensile strength of the first material and less than the ultimate tensile strength of the second material.
  • the ultimate tensile strength of the composite filament may be three times the ultimate tensile strength of the first material.
  • the ultimate tensile strength of the composite filament may be more than five times the ultimate tensile strength of the first material.
  • the first material may have an ultimate elongation that is greater than the ultimate elongation of the second material.
  • Ultimate elongation is the maximum increase in length a material can withstand before breaking.
  • the first material may have an ultimate elongation that is at least 25% greater than the second material.
  • the first material may have an ultimate elongation that is at least 50% greater than the second material.
  • the first material may have an ultimate elongation that is 75% greater than the second material, and may be twice the ultimate elongation of the second material. In this way, the first material may have an ultimate elongation that is between 25% and 100% greater than the second material. More specifically, the first material may have an ultimate elongation that is between 25% and 75% greater than the second material. 1 ] Although the first material may have different characteristics than the second material, as described above, it may be desirable that the first and second materials have certain characteristics that are similar. For instance, it is desirable for the first and second materials to be thermoplastic materials.
  • the first and second materials have similar glass transition temperatures, which is the temperature at which a material transitions between a hard state to a relatively rubbery or molten state, and is commonly referred to as the T g temperature of a material.
  • the glass transition temperature of the first material is within about 50 degrees C of the second material.
  • the glass transition temperature of the first material may be within 30 degrees C of the second material and may be within 20 degrees C.
  • the first and second material may have various characteristics. It should be understood that these characteristics may be chosen independently or they may be combined.
  • the first material may have a hardness (e.g. durometer) and a stiffness (i.e. Young's modulus) that are both significantly less than the second material.
  • the first material may have a greater ultimate elongation than the second material, but a lower Young's modulus than the second material.
  • a stress strain diagram is illustrated for filaments formed of a variety of materials.
  • a composite filament having an overall diameter of 1 .75 mm may be formed of a core of a first material and a jacket of a second material.
  • the jacket may be approximately 0.1 30 mm.
  • the first material may have a Young's modulus of 3,500-4,000 PSI and a flexural modulus of 7,500-1 0,000 PSI.
  • the first material may have a hardness of approximately 85 on the Shore A scale.
  • the first material may have an ultimate elongation of approximately 550%.
  • the first material may have an ultimate tensile strength of approximately 500-600 PSI.
  • the first material may have a glass transition temperature of approximately -30 degrees C.
  • the second material may have a Young's modulus of 50,000-60,000 PSI and a flexural modulus of 180,000-200,000 PSI.
  • the second material may have a hardness of approximately 75 on the Shore D scale.
  • the second material may have an ultimate elongation of approximately 330%.
  • the second material may have an ultimate tensile strength of approximately 4,500-5,000 PSI.
  • the second material may have a glass transition temperature of approximately -1 0 degrees C.
  • the composite filament may have a Young's modulus of 20,000-30,000 PSI.
  • the composite filament may have a hardness of 50-60 on the Shore D scale.
  • the composite filament may have an ultimate tensile strength of 2,000 - 2700 PSI.
  • the stress strain curves in Fig. 3 show the stress strain curve of the composite filament formed of an inner core material and an outer shell or jacket material.
  • the stress strain curves are also provided for a filament formed entirely of the first material and a filament formed entirely of the second material. These three curves are also compared against the stress strain curve for a filament formed of ABS.
  • the stress strain curve in Fig. 3 shows the results for an exemplary filament formed from two thermoplastic polyurethane resins.
  • the inner core is formed of an ester based thermoplastic polyurethane.
  • the outer shell or jacket is formed of an aromatic polyether based thermoplastic polyurethane.
  • the materials are co-extruded to form a composite filament in which the outer shell is bonded to the inner core.
  • the filament has a diameter of 1 .75 mm and a jacket thickness of 0.130 mm.
  • the core material generally remains in the elastic range throughout the entire curve, whereas, the jacket material and composite filament both have distinct elastic regions and plastic regions. The yield stress and ultimate tensile strength are both higher for the jacket material than for the composite filament.
  • the system 10 may be used to create a three-dimensional object as follows.
  • a length of filament 80 is selected having a diameter of between 1 mm and 10 mm. More specifically, the diameter may be less than 5 mm. In particular, the diameter may be between 1 .5 mm and 3 mm and in the present instance, the diameter is either 1 .75 mm or 3.0 mm.
  • the length of filament 80 is wound onto a spool 90 and the free end of the filament is fed into the feeder 50 of a deposition machine 10, such as an FFF.
  • the FFF 10 is controlled by a controller having digital instructions to produce a three-dimensional object based on a digital model of the object to be produced
  • the controller controls the feeder 50 to pull the filament from the spool.
  • the filament is formed of a relatively low durometer material so that the teeth of the drive wheel 52 can dig into or deform the filament radially inwardly to positively engage the filament to feed the filament forwardly.
  • the jacket material of the filament provides axial rigidity to prevent the filament from buckling as the drive wheel 52 urges the filament downwardly toward the extrusion head 20.
  • the feeder 50 feeds the filament through the extrusion head 20 to form a flow of melted material discharging from the nozzle 30 from melting the filament.
  • the filament 80 melts in the extrusion head 20 so that both the jacket material and the core material of the filament melt together.
  • the position of the nozzle 30 is controlled by the controller to move the nozzle within a plane to deposit a layer of melted filament 85 to form a layer of the three-dimensional object on a build platform. After depositing the first layer of material, the system then deposits a subsequent layer of melted filament to build-up a layer on the first layer.
  • the process continues by building up successive layers on top of one another, with the pattern of material being deposited during each layer being controlled by the controller by moving the nozzle along two axes to control the position of the nozzle within a plane.
  • the controller may then move the nozzle or the build platform along a third axes transverse the first two axes to raise or lower the nozzle relative to the build platform.
  • the object may be exposed to a solvent to alter the object.
  • the filament may be formed of two materials each having different solubilities.
  • the filament jacket may be formed of PVA, which is water soluble, while the filament core may be formed of polyurethane, which is not water soluble.
  • the harder material such as the jacket material
  • the flexibility of the object will be increased. In this way, the overall flexibility of the object can be increased after the object is formed using the FFF process.
  • a method for producing the filament 80 used in a deposition machine 10, such as an FFF machine is also provided.
  • the method provides a low- durometer extruded filament core having a jacket formed from a material that is harder than the core material.
  • the method of producing the filament comprises the step of melting a
  • the polymer used to make the core is selected to be a low durometer material having less than Shore 50D or between Shore 60A and 90A.
  • the polymer may be thermoplastic urethane or silicone.
  • the polymer may be a mixture of polymeric materials.
  • the filament may be substantially formed of thermoplastic elastomers, such as urethane, meaning that the filament is at least 50% thermoplastic elastomer, and more preferably is at least 70% thermoplastic elastomer, and most preferably is at least 90% thermoplastic elastomer.
  • the melted material is fed to an extrusion die according to any of a variety of known processes for feeding material to an extrusion die.
  • the extrusion die comprises a capillary die having a round die opening.
  • the feeder feeds the melted polymer to the die head so that the polymer is extruded from the die to form a cylindrical filament.
  • a puller pulls the extrusion to maintain tension on the filament as it emerges from the extrusion die.
  • the puller may comprise a pair of opposing belts forming a nip that engages the filament to pull the filament.
  • the jacket may be applied to the core using a variety of processes.
  • the jacket may be coextruded with the core.
  • the jacket material may be spray coated onto the core.
  • a coating head is used to apply the jacket to the core. Specifically, the core is fed through an inlet die of the coating head into a coating chamber that is filled with melted jacket material. The melted jacket material covers the core and the coated core then passes through an exit die having a round orifice that is larger than the core diameter.
  • the core or core/jacket combination may be cooled by any of a variety of means, such as by pulling the core or core/jacket combination through a bath of cooling fluid, such as water.
  • the core may be cooled before the jacket or the core and jacket combination may be cooled after the jacket is applied. After the core is cooled, the filament is wound onto a spool.
  • the process may include a mechanism for measuring a characteristic of the filament, such as the diameter of the filament. Any of a variety of mechanisms can be incorporated to measure the filament between the point that the filament emerges from the coating head and the filament is wound onto the spool.
  • a non-contact gauge is used for measuring the diameter of the filament.
  • the gauge may comprise a plurality of laser elements to measure the filament diameter.
  • the gauge may automatically detect the diameter of the filament while the filament is moving through the processing line. For instance, it may be desirable to maintain the filament diameter within a tolerance of +/- 0.05 mm of the desired diameter, such as 1 .75 mm +/- 0.05 mm. Similarly, the gauge may be used to measure the roundness of the filament to monitor whether the cross section of the filament is round or oval. For instance, it may be desirable to maintain the filament roundness within a tolerance of +/- 0.07 mm.
  • the gauge may provide a signal indicating that the filament diameter is above or below a pre-determined diameter.
  • the system may alter the speed of either the feeder feeding the melted material to the extrusion die or the system may alter the speed of the puller.
  • a central controller such as a microprocessor may control either the feeder or the puller in response to signals from the gauge indicative of the filament diameter being above or below the pre-determined diameter.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Textile Engineering (AREA)

Abstract

L'invention a trait à un appareil qui permet de former un objet grâce à un procédé additif communément appelé "impression 3D". L'appareil comprend un filament composite, comprenant une âme molle entourée d'une gaine plus dure qui fournit un support colonnaire visant à augmenter la rigidité axiale du filament, une buse chargée de déposer une couche de matériau fondu sur une surface et un dispositif d'alimentation servant à alimenter la buse en filament. Un élément chauffant fait fondre le filament et un régulateur ajuste la position de la buse dans un plan afin de réguler la configuration de la couche de matière fondue déposée par ladite buse. L'invention concerne en outre un procédé de formation de filament de polymère utilisé dans les dispositifs d'impression 3D. Le procédé comprend les étapes de fusion d'un premier matériau, ledit premier matériau comprenant un polymère, d'extrusion du premier matériau afin de produire une âme allongée et de formation d'une couche de deuxième matériau sur le noyau afin d'obtenir un filament enrobé, ledit deuxième matériau étant plus dur que le premier matériau.
PCT/US2015/063788 2014-12-03 2015-12-03 Filament amélioré pour modélisation par dépôt en fusion Ceased WO2016090164A1 (fr)

Applications Claiming Priority (2)

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US201462087195P 2014-12-03 2014-12-03
US62/087,195 2014-12-03

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WO2018162268A1 (fr) * 2017-03-09 2018-09-13 Philips Lighting Holding B.V. Filament de type cœur-écorce destiné à l'impression d'articles lisses fdm en (3d)
JP2021514430A (ja) * 2018-02-21 2021-06-10 スリーエム イノベイティブ プロパティズ カンパニー コアシースフィラメント及び接着剤をプリントする方法
US20210197444A1 (en) * 2018-08-24 2021-07-01 Signify Holding B.V. Stress releasing object by multiple-material fdm printing
CN113732303A (zh) * 2021-09-15 2021-12-03 浙江智熔增材制造技术有限公司 一种用于增材制造物体的丝材及其制备方法
CN114012094A (zh) * 2021-10-26 2022-02-08 珠海天威飞马打印耗材有限公司 三维成型丝料及其制备方法、三维打印机和三维成型方法
US20220259770A1 (en) * 2019-08-15 2022-08-18 3M Innovative Properties Company Core-sheath filament with a silicone-containing block copolymer core
US11673317B2 (en) 2019-08-07 2023-06-13 3M Innovative Properties Company Core-sheath filaments and methods of printing an adhesive
US11725308B2 (en) 2019-08-19 2023-08-15 3M Innovative Properties Company Core-sheath filaments including crosslinkable and crosslinked adhesive compositions and methods of making the same
US20230340304A1 (en) * 2019-12-23 2023-10-26 3M Innovative Properties Company Core-sheath filaments including thermally crosslinkable adhesive compositions
EP3680301B1 (fr) 2018-12-19 2024-05-15 tesa SE Procédé de fabrication d'un filament adhésif et filament adhésif

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Publication number Priority date Publication date Assignee Title
CN110382205A (zh) * 2017-03-09 2019-10-25 昕诺飞控股有限公司 用于打印光滑fdm 3d物品的芯-壳型丝
US11007707B2 (en) 2017-03-09 2021-05-18 Signify Holding B.V. Method for manufacturing a 3D item
WO2018162268A1 (fr) * 2017-03-09 2018-09-13 Philips Lighting Holding B.V. Filament de type cœur-écorce destiné à l'impression d'articles lisses fdm en (3d)
CN110382205B (zh) * 2017-03-09 2021-10-22 昕诺飞控股有限公司 用于打印光滑fdm 3d物品的芯-壳型丝
JP7466449B2 (ja) 2018-02-21 2024-04-12 スリーエム イノベイティブ プロパティズ カンパニー コアシースフィラメント及び接着剤をプリントする方法
JP2021514430A (ja) * 2018-02-21 2021-06-10 スリーエム イノベイティブ プロパティズ カンパニー コアシースフィラメント及び接着剤をプリントする方法
US12104288B2 (en) 2018-02-21 2024-10-01 3M Innovative Properties Company Core-sheath filaments and methods of printing an adhesive
US20210197444A1 (en) * 2018-08-24 2021-07-01 Signify Holding B.V. Stress releasing object by multiple-material fdm printing
EP3680301B1 (fr) 2018-12-19 2024-05-15 tesa SE Procédé de fabrication d'un filament adhésif et filament adhésif
US11673317B2 (en) 2019-08-07 2023-06-13 3M Innovative Properties Company Core-sheath filaments and methods of printing an adhesive
US12023855B2 (en) 2019-08-07 2024-07-02 3M Innovative Properties Company Core-sheath filaments and methods of printing an adhesive
US20220259770A1 (en) * 2019-08-15 2022-08-18 3M Innovative Properties Company Core-sheath filament with a silicone-containing block copolymer core
US11725308B2 (en) 2019-08-19 2023-08-15 3M Innovative Properties Company Core-sheath filaments including crosslinkable and crosslinked adhesive compositions and methods of making the same
US20230340304A1 (en) * 2019-12-23 2023-10-26 3M Innovative Properties Company Core-sheath filaments including thermally crosslinkable adhesive compositions
CN113732303A (zh) * 2021-09-15 2021-12-03 浙江智熔增材制造技术有限公司 一种用于增材制造物体的丝材及其制备方法
CN114012094A (zh) * 2021-10-26 2022-02-08 珠海天威飞马打印耗材有限公司 三维成型丝料及其制备方法、三维打印机和三维成型方法

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