# US 11,306,221 B2 · Additively manufactured article and method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,306,221 B2 - Document ID: US11306221B2 - Status: Granted - Kind: B2 - Application number: 17/418,907 - Filed: 2020-03-25 - Published: 2022-03-24 - Granted: 2022-04-19 - Earliest claimed: 2019-05-07 - Assignees: Shpp Global Technologies B.V. - Applicants: SHPP Global Technologies B.V. - Inventors: Rabeh Hosny Elleithy; Manojkumar Chellamuthu; Alex R. Delaney; Paul Dean Sybert; Kim Loan Thi Ly - Web page: https://patentgrep.com/patent/US11306221B2 ## CPC - C09D 169/00: Coating compositions based on polycarbonates; Coating compositions based on derivatives of polycarbonates - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B33Y 10/00: Processes of additive manufacturing - B33Y 70/00: Materials specially adapted for additive manufacturing - B33Y 80/00: Products made by additive manufacturing - C08G 64/14: containing a chain-terminating or -crosslinking agent - C08G 77/448: containing polycarbonate sequences - C08L 69/00: Compositions of polycarbonates; Compositions of derivatives of polycarbonates - B29K 2069/00: Use of PC, i.e. polycarbonates {or derivatives thereof}, as moulding material - B29K 2105/16: Fillers - C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D) - 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 - C08G: MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS - C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06) - 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 ## Abstract An article includes at least two contiguous layers containing a composition that includes a branched polycarbonate, optionally a linear carbonate-containing polymer, and 0 to less than 5 weight percent filler. The composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, which is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and the optional linear carbonate-containing polymer. The composition is further characterized by a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load. Also described is a method of additive manufacturing utilizing the composition. ## Claims ### Claim 1 An article, comprising: at least two contiguous layers; wherein the at least two contiguous layers comprise a composition comprising, based on the total weight of the composition, 10 to 100 weight percent of a branched polycarbonate; 0 to 90 weight percent of a linear carbonate-containing polymer selected from the group consisting of linear polycarbonates, linear polycarbonate-polysiloxanes, and combinations thereof; and 0 to less than 5 weight percent filler; wherein the composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, wherein the average mole percent branching is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and the linear carbonate-containing polymer; wherein the composition comprises 70 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer; and wherein the composition has a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load. ### Claim 2 (depends on 1) The article of claim 1, wherein the composition comprises the branched polycarbonate and the linear carbonate-containing polymer. ### Claim 3 (depends on 1) The article of claim 1, wherein the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer. ### Claim 4 (depends on 1) The article of claim 1, wherein the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent. ### Claim 5 (depends on 1) The article of claim 1, wherein the composition comprises 0 to 1 weight percent filler. ### Claim 6 (depends on 1) The article of claim 1, wherein the composition comprises the branched polycarbonate and the linear polycarbonate; the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear polycarbonate; the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and the composition comprises 0 to 1 weight percent filler. ### Claim 7 (depends on 1) The article of claim 1, wherein the composition comprises the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane; the composition comprises 95 to 100 weight percent total of the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane; the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and the composition comprises 0 to 1 weight percent filler. ### Claim 8 A method of additive manufacturing, the method comprising: converting a composition from a solid form to a molten form, wherein the composition is characterized by a glass transition temperature, and the molten form has a temperature 70 to 250° C. above the glass transition temperature; extruding the molten form to form a first molten extrusion; depositing the first molten extrusion in a predetermined pattern to form a first layer; further extruding the molten form to form a second molten extrusion; and depositing the second molten extrusion in a predetermined pattern to form a second layer having a lower surface in contact with an upper surface of the first layer, wherein the composition comprises, based on the total weight of the composition, 10 to 100 weight percent of a branched polycarbonate; 0 to 90 weight percent of a linear carbonate-containing polymer selected from the group consisting of linear polycarbonates, linear polycarbonate-polysiloxanes, and combinations thereof; and 0 to less than 5 weight percent filler; wherein the composition is characterized by an average mole percent branching of 0.06 to 2.4 mole percent, wherein the average mole percent branching is calculated as 100 times moles of branched carbonate units in the branched polycarbonate divided by the sum of moles of linear carbonate units in the branched polycarbonate and moles of linear carbonate units in the linear carbonate-containing polymer; wherein the composition comprises 70 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer; and wherein the composition has a melt flow rate of 1 to 20 grams per 10 minutes, determined according to ASTM D1238-13 at 300° C. and 1.2 kilogram load. ### Claim 9 (depends on 8) The method of claim 8, wherein the upper surface of the first layer has a temperature 20 to 200° C. above the glass transition temperature during the depositing the second molten extrusion. ### Claim 10 (depends on 8) The method of claim 8, wherein the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent. ### Claim 11 (depends on 8) The method of claim 8, wherein the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear carbonate-containing polymer. ### Claim 12 (depends on 8) The method of claim 8, wherein the composition comprises 0 to 1 weight percent filler. ### Claim 13 (depends on 8) The method of claim 8, wherein the composition comprises the branched polycarbonate and the linear polycarbonate; the composition comprises 95 to 100 weight percent total of the branched polycarbonate and the linear polycarbonate; the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and the composition comprises 0 to 1 weight percent filler. ### Claim 14 (depends on 8) The method of claim 8, wherein the composition comprises the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane; the composition comprises 95 to 100 weight percent total of the branched polycarbonate, the linear polycarbonate, and the linear polycarbonate-polysiloxane; the composition is characterized by an average mole percent branching of 0.06 to 2 mole percent; and the composition comprises 0 to 1 weight percent filler.