# US 10,307,935 B2 · Systems and methods for producing consumable powder > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,307,935 B2 - Document ID: US10307935B2 - Status: Granted - Kind: B2 - Application number: 15/576,374 - Filed: 2016-12-21 - Published: 2018-10-04 - Granted: 2019-06-04 - Earliest claimed: 2015-12-22 - Assignees: Structured Polymers, Inc. - Applicants: Structured Polymers, Inc. - Inventors: Vikram Devaraj; James K. Mikulak; Carl R. Deckard - Web page: https://patentgrep.com/patent/US10307935B2 ## CPC - B29B 9/12: characterised by structure or composition - B29B 7/88: Adding charges {, i.e. additives} - B29B 7/90: Fillers or reinforcements {, e.g. fibres} - B29B 9/06: in the form of filamentary material, e.g. combined with extrusion - B29B 9/14: fibre-reinforced - B33Y 10/00: Processes of additive manufacturing - B33Y 70/00: Materials specially adapted for additive manufacturing - B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials - C08J 3/12: Powdering or granulating - C08J 3/20: Compounding polymers with additives, e.g. colouring - B29B 9/08: by agglomerating smaller particles - B29B 9/16: Auxiliary treatment of granules - B29B 2009/125: {Micropellets, microgranules, microparticles} - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B29B: PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS - B33Y: 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 - C08J: WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H (working, e.g. shaping, of plastics B29) - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) ## Abstract A consumable polymeric based powder mixture may include a plurality of polymeric based particles that have a unitary construction. At least about 80% of the plurality of polymeric based particles may further have a generally cylindrical shape. The plurality of polymeric based particles may further have a particle length distribution span (PLDS) of not greater than about 1.2, where PLDS is equal to (L80−L20)/L50. ## Claims ### Claim 1 A consumable polymeric based powder mixture, the mixture comprising a plurality of polymeric based particles having a unitary construction, wherein at least about 80% of the plurality of polymeric based particles have a generally cylindrical shape. ### Claim 2 A consumable polymeric based powder mixture, the mixture comprising a plurality of polymeric based particles, wherein at least about 80% of the plurality of polymeric based particles have a generally cylindrical shape and wherein the plurality of polymeric based particles have a particle length distribution span (PLDS) of not greater than about 1.2, where PLDS is equal to (L80-L20)/L50. ### Claim 3 (depends on 1) The consumable polymeric based powder mixture of claim 1, wherein the at least one cross-section has a maximum width of not greater than about 100 microns. ### Claim 4 (depends on 1) The consumable polymeric based powder mixture of claim 1, wherein at least about 80% of the plurality of polymeric based particles comprise a cut artifact on a base of the polymeric based particles. ### Claim 5 (depends on 1) The consumable polymeric based powder mixture of claim 1, wherein at least a majority of the plurality of polymeric based particles has a homogeneous composition. ### Claim 6 (depends on 1) The consumable polymeric based powder mixture of claim 1, wherein at least a majority of the plurality of polymeric based particles have a length not greater than about 250 microns. ### Claim 7 (depends on 1) The consumable polymeric based powder mixture of claim 1, wherein the plurality of polymeric based particles have an average length of not greater than about 225 microns. ### Claim 8 A method of forming a consumable polymeric based powder mixture, the method comprising: providing a plurality of polymeric based tows comprising a plurality of polymeric based fibers; aggregating the plurality of polymeric based tows into an aggregated polymeric based tow; and successively forming a plurality of polymeric based particles from the aggregated polymeric based tow, wherein at least a majority of the polymeric based particles of the plurality of polymeric based particles has a unitary construction and wherein at least about 80% of the plurality of polymeric based particles have a generally cylindrical shape. ### Claim 9 (depends on 8) The method of claim 8, wherein successively forming a plurality of polymer based particles comprises cutting the aggregated polymeric based tow to form the plurality of polymer based particles. ### Claim 10 (depends on 8) The method of claim 8, wherein the method further comprises compressing the aggregated polymeric based tow before or during successively forming the plurality of polymer based particles. ### Claim 11 (depends on 8) The method of claim 8, wherein the method further comprises sifting the plurality of polymeric based particles. ### Claim 12 (depends on 8) The method of claim 8, wherein the method further comprises wet processing the plurality of polymeric based particles. ### Claim 13 (depends on 12) The method of claim 12, wherein wet processing further comprises removing any processing aides added to the prior to forming the plurality of polymeric based particles. ### Claim 14 (depends on 12) The method of claim 12, wherein wet processing further comprises introducing additional additives to the plurality of polymeric based particles to improve the processing properties of the powder, the mechanical properties of the powder, slow thermal, UV or other types of polymer degradation, change the optical properties of the powder, introduce improvements in fire resistance, or change electrical or other measureable properties of the powder. ### Claim 15 (depends on 12) The method of claim 12, wherein wet processing comprises a phenol, alcohol or other treatment to pre-shrink the plurality of polymeric based particles. ### Claim 16 (depends on 2) The consumable polymeric based powder mixture of claim 2, wherein the at least one cross-section has a maximum width of not greater than about 100 microns. ### Claim 17 (depends on 2) The consumable polymeric based powder mixture of claim 2, wherein at least about 80% of the plurality of polymeric based particles comprise a cut artifact on a base of the polymeric based particles. ### Claim 18 (depends on 2) The consumable polymeric based powder mixture of claim 2, wherein at least a majority of the plurality of polymeric based particles has a homogeneous composition. ### Claim 19 (depends on 2) The consumable polymeric based powder mixture of claim 2, wherein at least a majority of the plurality of polymeric based particles have a length not greater than about 250 microns. ### Claim 20 (depends on 2) The consumable polymeric based powder mixture of claim 2, wherein the plurality of polymeric based particles have an average length of not greater than about 225 microns.