High strength 3d-printed polymer structures and methods of formation
AssigneeU.S. Army Combat Capabilities Development Command Army Research Laboratory
InventorsRyan M. Dunn, Kevin R. Hart, Eric D. Wetzel
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Abstract
A polymer body includes a first thermoplastic polymer, and a second thermoplastic polymer. The first thermoplastic polymer and the second thermoplastic polymer form a continuous solid structure. The first thermoplastic polymer forms an external supporting structure that at least partially envelops the second thermoplastic polymer. A first flow temperature of the first thermoplastic polymer is at least 10° C. higher than a second flow temperature of the second thermoplastic polymer. The first thermoplastic polymer may be removable by exposure to a selective solvent.
Claims23
A polymer body comprising:
- a first thermoplastic polymer;
- and
- a second thermoplastic polymer,
- wherein the first thermoplastic polymer and the second thermoplastic polymer form a continuous solid structure,
- wherein the first thermoplastic polymer forms an external supporting structure that at least partially envelops the second thermoplastic polymer, and
- wherein a first flow temperature of the first thermoplastic polymer is at least 10° C. higher than a second flow temperature of the second thermoplastic polymer.
A multi-component thermoplastic filament comprising:
- a first thermoplastic component;
- and
- a second thermoplastic component,
- wherein the first thermoplastic component and second thermoplastic component comprise a regular geometric arrangement, and
- wherein the first thermoplastic component is configured to be removed by exposure to a selective solvent.
A method for creating a high strength thermoplastic body, the method comprising:
- providing a first thermoplastic polymer;
- providing a second thermoplastic polymer;
- forming a three-dimensional (3D) solid from the first thermoplastic polymer and the second thermoplastic polymer, wherein the 3D solid comprises a continuous solid structure comprising the second thermoplastic polymer, wherein the first thermoplastic polymer forms an external supporting structure that at least partially envelops the second thermoplastic polymer, and wherein a first flow temperature of the first thermoplastic polymer is at least 10° C. higher than a second flow temperature of the second thermoplastic polymer;
- and
- annealing the 3D solid at a temperature below the first flow temperature and above the second flow temperature.
A method for creating a high strength thermoplastic structure, the method comprising:
- three-dimensional (3D) printing a thermoplastic polymer;
- coating the thermoplastic polymer with a coating material to form a thermoplastic structure;
- annealing the thermoplastic structure;
- and
- removing the coating material from the thermoplastic structure without changing a mechanical integrity of a remaining portion of the thermoplastic structure.
A method for creating a high strength thermoplastic structure, the method comprising:
- three-dimensional (3D) printing a thermoplastic polymer;
- embedding the thermoplastic polymer into granular particles to form a thermoplastic structure;
- annealing the thermoplastic structure;
- and
- removing the granular particles from the thermoplastic structure.
Dependencies are inferred from the claim text.