Method of making a three-dimensional object using a poly(ether ether ketone) polymeric component
OwnerStéphane Jeol, Nancy J. Singletary +2inventors
InventorsStéphane Jeol, Nancy J. Singletary, Hai Van, James Brown Hicks
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Abstract
The present disclosure relates to method of making three-dimensional (3D) objects using an additive manufacturing system wherein the part material comprises a polymeric component comprising at least one poly(ether ether ketone) polymer (PEEK) having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by GPC), for example in the form of filaments or spherical particles, for use in additive manufacturing systems to print 3D objects.
Claims21
A method of making a three-dimensional (3D) object, comprising extruding a part material to print layers of the 3D object, wherein the part material comprises a polymeric component selected from the group consisting of:
- i) at least one poly(ether ether ketone) polymer (PEEK) having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards), and
- ii) at least two PEEK polymers having different Mw, the blend thereof having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards),
- wherein the term PEEK polymer denotes any polymer comprising at least 95 mol. % of recurring units (RPEEK) of formula (J-A), based on the total
- number of moles in the polymer:
- where
- R′, at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sultanate, alkyl sultanate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium;
- and
- J′, for each R′, is independently zero or an integer ranging from 1 to 4.
A filament material for its use in 3D printing having a cylindrical geometry and a diameter comprised between 0.5 and 5 mm±0.15 mm, said filament material comprising a polymeric component selected from the group consisting of:
- i) at least one poly(ether ether ketone) polymer (PEEK) having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards), and
- ii) at least two PEEK polymers having different Mw, the blend thereof having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards),
- wherein the term PEEK polymer denotes any polymer comprising at least 95 mol. % of recurring units (RPEEK) of formula (J-A), based on the total number
- of moles in the polymer:
- where
- R′, at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sultanate, alkyl sultanate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium;
- and
- J′, for each R′, is independently zero or an integer ranging from 1 to 4;
- wherein the polymeric component comprises at least 80 wt. % of the PEEK polymer(s), based on the total weight of polymeric component of the filament.
A method for the manufacture of a filament to be used in the manufacture of three-dimensional objects, comprising:
- using a part material comprising a polymeric component selected from the group consisting of:
- i) at least one poly(ether ether ketone) polymer (PEEK) having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards), and
- ii) at least two PEEK polymers having different Mw, the blend thereof having a Mw ranging from 75,000 to 100,000 g/mol (as determined by gel permeation chromatography (GPC) using phenol and trichlorobenzene (1:1) at 160° C., with polystyrene standards),
- wherein the term PEEK polymer denotes any polymer comprising at least 95 mol. % of recurring units (RPEEK) of formula (J-A), based on the total number of moles in the polymer:
- where
- R′, at each location, is independently selected from the group consisting of halogen, alkyl, alkenyl, alkynyl, aryl, ether, thioether, carboxylic acid, ester, amide, imide, alkali or alkaline earth metal sulfonate, alkyl sulfonate, alkali or alkaline earth metal phosphonate, alkyl phosphonate, amine and quaternary ammonium, and
- J′, for each R′, is independently zero or an integer ranging from 1 to 4.
Dependencies are inferred from the claim text.