# US 10,370,530 B2 · Methods for solid freeform fabrication > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,370,530 B2 - Document ID: US10370530B2 - Status: Granted - Kind: B2 - Application number: 15/054,500 - Filed: 2016-02-26 - Published: 2017-08-31 - Granted: 2019-08-06 - Earliest claimed: 2016-02-26 - Assignees: Ricoh Company, Ltd.; University of Washington - Applicants: Andrew J. Boydston; Adam Edward Goetz; Chang-Uk Lee; Gregory Isaac Peterson; Mark A. Ganter; Duane W. Storti; Mete Yurtoglu - Inventors: Andrew J. Boydston; Adam Edward Goetz; Chang-Uk Lee; Gregory Isaac Peterson; Mark A. Ganter; Duane W. Storti; Mete Yurtoglu - Web page: https://patentgrep.com/patent/US10370530B2 ## CPC - C08L 61/16: of ketones with phenols - B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber - B33Y 70/00: Materials specially adapted for additive manufacturing - C08L 71/00: Compositions of polyethers obtained by reactions forming an ether link in the main chain (of polyacetals C08L59/00; of epoxy resins C08L63/00; of polythioether-ethers C08L81/02; of polyether-sulfones C08L81/06); Compositions of derivatives of such polymers - B29C 35/0805: {using electromagnetic radiation} - B29C 2035/0827: {using UV radiation} - B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material - B29K 2079/08: {PI, i.e. polyimides or derivatives thereof} - B29K 2995/0077: Yield strength; Tensile strength - B33Y 10/00: Processes of additive manufacturing - C08G 2650/40: containing ketone groups, e.g. polyarylethylketones, PEEK or PEK - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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) - 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 - B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS ## Abstract The present invention provides high performance polymer (HPP) compositions, methods, processes, and systems for the manufacture of three-dimensional articles made of polymers using molding or 3D printing. The HPP compositions comprise a first HPP dissolved in a solvent and a second HPP present as a solid. ## Claims ### Claim 1 A method for manufacturing a three-dimensional article, the method comprising: a. depositing a powder of a first high performance polymer (HPP) on a build plate to form a powder bed; b. depositing a composition at selected locations on the powder bed wherein the composition comprises: a homogeneous mixture of a second HPP dissolved in a solvent; wherein the composition further comprises particles of a third HPP that are dispersed in the homogeneous mixture of the second HPP and the solvent; and wherein the particles of the third HPP are insoluble in the homogeneous mixture; c. exposing the deposited composition to a stimulus to form a polymer layer of the three-dimensional article; and d. repeating steps (a)-(c) to manufacture remainder of the three-dimensional article. ### Claim 2 (depends on 1) The method of claim 1, wherein the composition has a viscosity of about 1 cP to about 50 cP. ### Claim 3 (depends on 1) The method of claim 1, wherein the second HPP comprises a polyketone. ### Claim 4 (depends on 2) The method of claim 2, wherein the polyketone comprises polyetheretherketone (PEEK), polyaryletherketone (PAEK), polyetherketone (PEK), polyetherketoneketone (PEKK) polyetheretheretherketone (PEEEK), polyetheretherketoneketone (PEEKK), polyetherketoneetheretherketone (PEKEKK), or polyetherketoneketoneketone (PEKKK). ### Claim 5 (depends on 1) The method of claim 1, wherein the third HPP comprises polyimides, polyketones, reduced forms of polyketones, and polyethersulfones, and wherein the third HPP is not soluble in the solvent. ### Claim 6 (depends on 1) The method of claim 1, where the stimulus is radiation or heat. ### Claim 7 (depends on 5) The method of claim 5, wherein radiation is ultraviolet radiation, visible radiation, infrared radiation, electron beam radiation, or combinations thereof. ### Claim 8 (depends on 1) The method of claim 1, further comprising the step of curing wherein curing is done by chemical curing or thermal curing. ### Claim 9 (depends on 5) The method of claim 5, wherein the thermal curing is carried out at about 300° C. or above. ### Claim 10 A method for manufacturing a three-dimensional article, the method comprising: a. depositing a composition comprising: a homogeneous mixture of a first high performance polymer (HPP) dissolved in a solvent; wherein the composition further comprises particles of a second HPP that are dispersed in the homogeneous mixture of the first HPP and the solvent; and wherein the particles of the second HPP are insoluble in the homogeneous mixture; into a mold to form the three-dimensional article; and b. removing the three-dimensional article from the mold. ### Claim 11 (depends on 10) The method of claim 10, wherein the first HPP comprises a polyketone. ### Claim 12 (depends on 10) The method of claim 10, wherein the second HPP comprises polyimides, polyketones, reduced forms of polyketones, and polyethersulfones, and wherein the second HPP is not soluble in the solvent. ### Claim 13 (depends on 10) The method of claim 10, further comprising the step of curing wherein curing is done by chemical curing or thermal curing. ### Claim 14 (depends on 13) The method of claim 13, wherein the thermal curing is carried out at a temperature below the glass transition temperature of the first HPP. ### Claim 15 (depends on 13) The method of claim 13, wherein the thermal curing is carried out at a temperature above the glass transition temperature of the first HPP.