# US 2014/0197579 A1 · Polymer additive layer manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0197579 A1 - Document ID: US20140197579A1 - Status: Published application - Kind: A1 - Application number: 14/118,808 - Filed: 2012-05-09 - Published: 2014-07-17 - Earliest claimed: 2011-05-20 - Assignees: Eads UK Limited - Applicants: Eads UK Limited - Inventors: Jonathan Meyer - Web page: https://patentgrep.com/patent/US20140197579A1 ## CPC - B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting - B29C 33/448: {destructible (B29C33/52 takes precedence; in particular used in injection moulding B29C45/4457)} - B33Y 10/00: Processes of additive manufacturing - B33Y 70/00: Materials specially adapted for additive manufacturing - B29K 2055/02: ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers - B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material - Y10T 428/31946: Next to second aldehyde or ketone condensation product - 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 - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract An additive layer manufacturing method for producing a shaped article, comprising providing a powdered thermoplastic polymer material (7, 8) having a re-solidification temperature at most 10% below its melting temperature on the Celsius scale, depositing successive layers of the powdered polymer material (7, 8) and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer. ## Claims ### Claim 1 An additive layer manufacturing (ALM) method for producing a shaped article, comprising providing a powdered thermoplastic polymer material having a re-solidification temperature at most 10% below its melting temperature on the Celsius scale, depositing successive layers of the powdered polymer material and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer. ### Claim 2 (depends on 1) A method according to claim 1, wherein the polymer is a semi-crystalline polymer. ### Claim 3 (depends on 1) A method according to claim 1, wherein the polymer is selected from the group comprising polyaryletherketones, polyetheretherketones (PEEK), polyetherketones (PEK), polyetherimides (PEI), or acrylonitrile butadiene styrenes (ABS). ### Claim 4 (depends on 1) A method according to claim 1, wherein the polymer has a re-solidification temperature at most 5% below its melting temperature on the Celsius scale. ### Claim 5 (depends on 1) A method according to claim 1, wherein the shaped article is constructed on a horizontal, planar substrate. ### Claim 6 (depends on 5) A method according to claim 5, wherein the substrate is moveable in the vertical direction. ### Claim 7 (depends on 1) A method according to claim 1, wherein the shaped article is constructed within a sintering chamber. ### Claim 8 (depends on 7) A method according to claim 7, wherein the sintering chamber is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer. ### Claim 9 (depends on 7) A method according to claim 7, wherein the sintering chamber is maintained at a temperature below the continuous service temperature of the polymer material. ### Claim 10 (depends on 7) A method according to claim 7, wherein the sintering chamber is maintained at a temperature below the temperature at which the strength of the polymer material after 2,000 hours at that temperature is decreased by at least 10% due to thermal aging. ### Claim 11 (depends on 1) A method according to claim 1, wherein the un-sintered polymer material is re-used for producing another article according to the method of claim 1. ### Claim 12 (depends on 1) A method according to claim 1, wherein the polymer is selectively sintered using a laser source. ### Claim 13 (depends on 1) A method according to claim 1, further comprising producing a support structure and then producing the article upon the support structure, wherein the support structure and the article are produced using the same ALM method. ### Claim 14 (depends on 13) A method according to claim 13, wherein the support structure includes an array of slender struts. ### Claim 15 (depends on 1) An article produced according to the method of claim 1. ### Claim 16 (depends on 15) An article according to claim 15, which is a component, a sample, a model, or a prototype. ### Claim 17 An additive layer manufacturing (ALM) method for producing a shaped article, comprising providing a powdered thermoplastic polymer material having a re-solidification temperature not significantly below its melting temperature on the Celsius scale, depositing successive layers of the powdered polymer material and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer. ### Claim 18 An additive layer manufacturing (ALM) method for producing a shaped article, comprising providing a powdered thermoplastic polymer material, depositing successive layers of the powdered polymer material and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer, and wherein the polymer is selected from the group comprising polyaryletherketones, polyetheretherketones (PEEK), polyetherketones (PEK), polyetherimides (PEI), or acrylonitrile butadiene styrenes (ABS). ### Claim 19 An additive layer manufacturing (ALM) method for producing a shaped article, comprising providing a powdered thermoplastic polymer material, depositing successive layers of the powdered polymer material and selectively sintering each layer prior to deposition of the subsequent layer so as to form the article, wherein during its production the article is maintained at a temperature above the glass transition temperature and significantly below the re-solidification temperature of the polymer, and wherein the polymer has a continuous service temperature in excess of 100 degrees Celsius, and preferably in excess of 150 degrees Celsius.