Method of printing parts with a high-performance consumable materials with electrophotography based additive manufacturing system

A method for printing a three-dimensional part with an electrophotography-based additive manufacturing system having an electrophotography engine, a belt, a nip roller, build platform, and a gantry that moves previously printed layers of the three-dimensional part relative to the nip roller, the method comprising:

• providing a part material to a photoconductive surface of the electrophotography-based additive manufacturing system, the part material compositionally comprising a charge control agent, and a thermoplastic material having a heat deflection temperature greater than about 150° C., and has a powder form, wherein the powder form has a D90/D50 particle size distribution and a D50/D10 particle size distribution each ranging from about 1.00 to about 1.40;
• triboelectrically charging the part material to a Q/M ratio having a negative charge or a positive charge, and a magnitude ranging from about 5 micro-Coulombs/gram to about 50 micro-Coulombs/gram;
• developing layers of the three-dimensional part from the charged part material with the electrophotography engine, wherein the photoconductive surface of the electrophotography engine is charged with a charge opposite that of the part material;
• electrostatically attracting the developed layers from the electrophotography engine to the belt, wherein a charge that is the same charge as on the electrophotography engine and of a greater magnitude than the charge on the electrophotography engine such that the developed layers are electrostatically transferred from the electrophotography engine to the belt;
• heating the developed layers on the belt;
• heating the build platform and the previously printed layers of the three-dimensional part;
• moving the heated developed layers to the nip roller;
• registering the heated developed layers with the previously printed layers of the three-dimensional part proximate the nip roller and transfusing the heated developed layers to the previously printed layers of three-dimensional part utilizing heat and pressure over time as the gantry moves the previously printed layers and the build platform relative to the nip roller;
• and
• wherein the thermoplastic material has a backbone chain that includes a structure comprising: