# US 12,759,243 B2 · Printing platform for extrusion additive manufacturing

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- Number: US 12,759,243 B2
- Document ID: US12759243B2
- Status: Granted
- Kind: B2
- Application number: 18/547,898
- Filed: 2022-01-26
- Published: 2024-04-25
- Granted: 2026-10-13
- Earliest claimed: 2021-02-26
- Assignees: Basell Polyolefine GmbH; Albert-Ludwigs-Universität Freiburg
- Applicants: Basell Polyolefine GmbH; Albert-Ludwigs-Universität Freiburg
- Inventors: Carl Gunther Schirmeister; Erik Hans Licht; Karsten Schmitz; Yannic Kessler; Klaus Klemm; Jürgen Rohrmann; Dieter Langenfelder; Mikhail Dureev; Rolf Muelhaupt; Mirco Müller; Steer Peter; Kolano Benjamin
- Web page: https://patentgrep.com/patent/US12759243B2

## CPC

- B29C 64/40: Structures for supporting 3D objects during manufacture and intended to be sacrificed after completion thereof
- B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM]
- B29K 2023/06: {PE, i.e. polyethylene}
- B29K 2023/12: {PP, i.e. polypropylene}
- B33Y 10/00: Processes of additive manufacturing
- B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor
- B33Y 70/00: Materials specially adapted for additive manufacturing
- 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)
- 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
- 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

## Abstract

An extrusion-based additive manufacturing process including the step of selectively depositing a molten thermoplastic material (P) on a film or sheet made from or containing a polymer blend obtained by melt blending a mixture made from or containing: (A) 60% to 98.8% by weight of a polyolefin; (B) 0.1% to 30% by weight of a compatibilizer; (C) 0.05% to 20% by weight of an amino resin; and (D) 0% to 5% by weight of an additive, wherein the amounts of (A), (B), (C) and (D) are based on the total weight of (A)+(B)+(C)+(D).

## Claims

### Claim 1

An extrusion-based additive manufacturing process comprising the step of:
(a) selectively depositing a molten thermoplastic material (P) on a film or sheet comprising a polymer blend obtained by melt blending a mixture comprising
(A) 60% to 98.8% by weight of a polyolefin;
(B) 0.1% to 30% by weight of a compatibilizer;
(C) 0.05% to 20% by weight of an amino resin; and
(D) 0% to 5% by weight of an additive,
wherein the amounts of (A), (B), (C), and (D) are based on the total weight of (A)+(B)+(C)+(D), the total weight being 100%.

### Claim 2 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein the step of selectively depositing the molten thermoplastic material (P) on the film or sheet comprises the steps of:
(i) placing the film or sheet on a printing platform of a 3D printing device, thereby permitting the film or sheet to serve as a printing plate;
(ii) selectively depositing the molten thermoplastic material (P) on the printing plate, thereby obtaining a 3D printed article; and
(iii) optionally removing the printing plate from the 3D printed article.

### Claim 3 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein the thermoplastic material (P) is selected from the group consisting of polyolefins, polylactic acid (PLA), polyamides (PA), polycarbonates (PC), polyurethanes (TPU), polyesters (PE), polyethylene terephthalates (PET), glycol-modified polyethylene terephthalates (PETG), polyhydroxy butyrate (PHB), polyetherketones, polyacrylates, polymethacrylates, poly(methyl methacrylates), polythiophenylene, acrylonitrile-butadiene-styrene polymers (ABS), acrylonitrile-styrene-acrylate polymers (ASA), the polymer blend, and combinations thereof.

### Claim 4 (depends on 1)

The extrusion-based manufacturing process according to claim 1, wherein the thermoplastic material (P) is a polyolefin composition selected from the group consisting of:
(I) a polyethylene composition having a melt flow index MIE at 190° C. with a load of 2.16 kg, according to ISO 1133-2:2011, of at least 0.1 g/10 min., comprising:
a1) 1-40% by weight of a polyethylene component having a weight average molar mass Mw, as measured by GPC, equal to or higher than 1,000,000 g/mol,
b1) 1-95% by weight of a polyethylene component having a Mw value from 50,000 to 500,000 g/mol, and
c1) 1-59% by weight of a polyethylene component having a Mw value equal to or lower than 5,000 g/mol,
wherein the amounts of components a1), b1), and c1) are referred to the total weight of a1)+b1)+c1), the total weight being 100%;
(II) a heterophasic polypropylene composition containing a matrix and a dispersed elastomeric phase, wherein the heterophasic polypropylene composition comprises:
a2) up to 65 wt. % of a propylene homopolymer or a propylene-ethylene copolymer as the matrix, and
b2) up to 35 wt. % of a propylene-ethylene copolymer as the dispersed elastomeric phase,
wherein the amounts of components a2) and b2) are referred to the total weight of a2)+b2), the total weight being 100%, and
wherein the heterophasic polypropylene composition has
a xylene-soluble content of from 15 wt. % to 50 wt. %, based upon the total weight of the heterophasic polypropylene composition,
an intrinsic viscosity of the fraction soluble in xylene at 25° C. ranging from 1.5 to 6.0 dl/g,
an ethylene content from 10 wt. % to 50 wt. %, based upon the total weight of the heterophasic polypropylene composition, and
a melt flow rate MFR L (ISO 1133, condition L, 230° C. and 2.16 kg load) of from 0.5 to 100 g/10 min.;
(III) a polypropylene composition comprising:
a3) 20-60% by weight of a heterophasic propylene copolymer;
b3) 5-33% by weight of a propylene homopolymer or copolymer, wherein the copolymer comprises up to 5% by weight, based on the total weight of the copolymer, of an alpha-olefin selected from the group consisting of ethylene, 1-butene, 1-hexene, and 1-octene;
c3) 2-15% by weight of an elastomeric block copolymer comprising styrene,
d3) 4-32% by weight of an elastomeric ethylene copolymer,
e3) 5-50% by weight of an inorganic filler, and
f3) 0.1-5% by weight of a compatibilizer,
wherein the amounts of components a3), b3), c3), d3), e3), and f3) are referred to the total weight of a3), b3), c3), d3), e3) and f3), which amounts to 100%, and
wherein the polypropylene composition has a melt flow rate MFR (230° C., load 2.16 kg, measured according to ISO 1133-2:2011) of at least 1.0 g/10 min; and
(IV) combinations thereof.

### Claim 5 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein the thermoplastic polymer (P) is fed to a 3D printing device in a form of a filament or of a pellet.

### Claim 6 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein component (A) is a propylene polymer selected from the group consisting of propylene homopolymers and propylene copolymers with an alpha-olefin of formula CH2═CHR, where R is H or a linear or branched C2-C8 alkyl, wherein the propylene copolymer comprises up to 6.0% by weight of units deriving from the alpha-olefin, based on the weight of the propylene copolymer.

### Claim 7 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein component (B) is a polyolefin selected from the group consisting of polyethylenes, polypropylenes, and mixtures thereof, functionalized with a compound selected from the group consisting of maleic anhydride, C1-C10 linear or branched dialkyl maleates, C1-C10 linear or branched dialkyl fumarates, itaconic anhydride, C1-C10 linear or branched itaconic acid, dialkyl esters, maleic acid, fumaric acid, itaconic acid, and mixtures thereof.

### Claim 8 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein component (C) is selected from the group consisting of urea-formaldehyde resins, melamine-formaldehyde resins, melamine-urea copolymer resins, and mixtures thereof.

### Claim 9 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein component (D) is selected from the group consisting of antistatic agents, anti-oxidants, slipping agents, anti-acids, melt stabilizers, nucleating agents, and combinations thereof.

### Claim 10 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein the film or sheet is a monolayer film having a thickness of from 1 to 5000 μm.

### Claim 11 (depends on 1)

The extrusion-based additive manufacturing process according to claim 1, wherein the sheet is a multilayer article comprising a top layer and a base layer, wherein the top layer comprises the polyolefin polymer blend and has a thickness from 1 to 5000 μm and the base layer comprises a material selected from the group consisting of metals, polymers, ceramic, glass, and combinations thereof, and has a thickness of from 3 μm to 20,000 μm.

### Claim 12 (depends on 11)

The extrusion-based additive manufacturing process according to claim 11, wherein the base layer is a metallic layer comprising a metal selected from the group consisting of aluminum, copper, iron, steel, titanium, lithium, gold, silver, manganese, platinum, palladium, nickel, cobalt, tin, vanadium, chromium, alloys comprising the metals, and combinations thereof.