Core-shell morphology of composite filaments for use in extrusion-based additive manufacturing systems

A consumable filament for use in an additive manufacturing system, the consumable filament comprising:

• a core portion extending along a longitudinal length of the consumable filament, the core portion compositionally comprising a matrix of a first base polymer and glass beads, glass fiber, carbon fiber particles or combinations thereof dispersed in the matrix, wherein the particles comprise between at least about 20 percent to about 85 percent by volume of the core portion;
• and
• a shell portion extending along the longitudinal length of the consumable filament and at least partially encasing the core portion, the shell portion compositionally comprising a second base polymer, wherein the consumable filament is configured to be supplied through a feed line to an extruder of the additive manufacturing system, melted and extruded through a nozzle of the extruder, wherein the shell retains the particles within the core portion and is configured to remain substantially intact as the filament is extruded, to thereby reduce wear on the nozzle and other machinery of the additive manufacturing system relative to a filament loaded with a similar amount of particles throughout a cross-section of the filament such that the filament is configured to print a loaded polymer based 3D part.