Abstract: A computer-implemented method, system and computer program product for modeling a manufacturing process. Snapshots of the system are received, where each snapshot includes a time that the snapshot was taken and a state of the system at that time. Possible transitions paths in a state diagram exhibited by the system are then identified based on the snapshots. A transition path out of the identified transition paths that most likely corresponds to the sequence of state changes exhibited by the system is selected based on information pertaining to a typical time taken by the system from one state to another. A predicted time that the system entered each state of the selected transition path between selected states of the snapshots is determined based on such information as well as the time at which the snapshots were taken. An issue related to the manufacturing process is predicted based on such predicted times.

Abstract: A composition useful for additive manufacturing is comprised of a thermoplastic elastomer blended with an aliphatic polyketone, wherein the thermoplastic elastomer is a continuous phase having dispersed therein separated domains of polyketone. The composition is useful for additive printing methods employing heating and extrusion of the composition to form extrudates that are printed an article comprised of fused layers of the composition. The composition facilitates the formation of extrusion based elastomeric additive manufactured articles.

Abstract: An additive manufacturing composition useful as a support material for common build materials (e.g., polyamide or polyester) is comprised of a blend of an elastomer toughened styrenic polymer having discreet domains of polymerized conjugate diene dispersed within a styrenic matrix and a vinyl aromatic-maleic anhydride copolymer. The composition may be used as a support material in additive manufacturing methods such as extrusion methods (e.g., fused filament fabrication). The compositions may be tuned to realize the desired adherence to facilitate the desired support while also allowing for the mechanical removal without breakage of the underlying part or residual adhered support material.

Abstract: Useful thermoplastic polymer powders are formed by a method comprising: cooling a foam comprised of a thermoplastic foam below the brittleness temperature of the thermoplastic polymer, wherein the foam has an average strut dimension of 10 to 500 micrometers, and comminuting the cooled foam to form a thermoplastic polymer powder. The method allows for the efficient grinding of the thermoplastic polymer having improved morphology and desirable characteristics such as dry flow without flow aids.

Abstract: Spherical thermoplastic polymer powders useful for additive manufacturing may be made at high throughputs by a method comprising polymer in a dispersing medium at a temperature above the polymer melting temperature (Tm) under shear for short times (e.g., less than 30 minutes) to form a mixture that is then rapid (faster than ambient cooling) cooled below Tm. The method is particularly useful for thermoplastic polymers having a high melt flow index (MFI) or low capillary viscosity at high shear (˜1000 s?1) within 20 or 30° C. of the polymer's melt temperature. The method may also include a crystallizing temperature below Tm and above the glass transition temperature Tg of the polymer to crystallize amorphous polymers or increase the crystallinity of semi-crystalline polymers.

Abstract: An additive manufacturing composition useful as a support material for common build materials (e.g., polyamide or polyester) is comprised of a blend of an elastomer toughened styrenic polymer having discreet domains of polymerized conjugate diene dispersed within a styrenic matrix and a vinyl aromatic-maleic anhydride copolymer. The composition may be used as a support material in additive manufacturing methods such as extrusion methods (e.g., fused filament fabrication). The compositions may be tuned to realize the desired adherence to facilitate the desired support while also allowing for the mechanical removal without breakage of the underlying part or residual adhered support material.

Abstract: A polymeric composition comprised of poly(methylmethacrylate) (PMMA) and polylactic acid (PLA) having a surface charge potential of at least about 50 volts in the absence of any other charge enhancing component may be made by melt blending PMMA and PLA, extruding the melt blend through a die and cooling at a rate through Tg of the PLA of at 10° C./min to 1000° C./second. The polymeric composition may be made by melt blowing into a nonwoven fabric. The nonwoven fabric may be charged to a surface potential of at least about 50 electron volts. Such filters may have greater than 95% efficiency at a pressure drop of less than 2 mm Hg even after being exposed to high temperatures (~70° C.) for an hour or more.

Abstract: A blended polymer comprising, an amorphous thermoplastic polymer and a thermoplastic semi-crystalline polymer, each of the polymers being essentially miscible in the other and being blended at a weight ratio of amorphous polymer/semi-crystalline polymer of greater that 0.05 to about 20 forms a melt blown nonwoven fabric having essentially no defects with long fiber lengths having uniform diameters. The nonwoven fabrics when used as a filter may have greater than 95% efficiency at a pressure drop of less than 2 mm Hg even after being exposed to high temperatures (˜70° C.) for an hour or more.

Abstract: Polymer powders useful for additive manufacturing may be made by contacting carbon dioxide and a crystallizable polymer having at least one carbonyl, sulfur oxide or sulfone group; permeating the carbon dioxide into the polymer for a crystallizing time sufficient to induce crystallization forming an induced crystalized polymer; removing the carbon dioxide; and forming induced crystalized polymer particles having a D90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 100 micrometers equivalent spherical diameter. The carbon dioxide is desirably supercritical carbon dioxide for at least a portion of the crystallizing time. The polymer powders upon heating during additive manufacturing may result in a polymer having less crystallinity or become amorphous.

Abstract: An end capped condensation polymer may be formed by heating a condensation polymer in the presence of an end capping compound to form cleaved condensation polymer reacting at least a portion of the cleaved condensation polymer with the end capping compound to form the end capped condensation polymer. The end capped condensation polymers may be used to form additive manufactured articles having high solids loading and improved processing due to improved rheological behavior.

Abstract: An additive manufactured condensation polymer article with improved build or Z direction strength may be formed by physically mixing or depositing thereon a chain extender that extends and chemically bonds the polymer chains within and between layers upon heating and fusing during the additive manufacturing process.

Abstract: Copolymers of condensation polymers are formed by a method of cleaving and reacting with a chain extender to form an end capped cleaved condensation polymer that is further reacted with a second compound that may be comprised of a further chain extender and condensation polymer that react with a reactive group still remaining in the chain extender capping the cleaved condensation polymer. The method allows the formation of block copolymers, branched copolymers and star polymers of differing condensation polymers bonded through the residue of a chain extender.

Abstract: Compositions useful for making additive manufactured articles are comprised of a styrenic thermoplastic elastomer, the styrenic thermoplastic elastomer being comprised of a block copolymer being comprised of at least two blocks of a vinyl aromatic monomer and at least one block of a conjugated diene monomer, and a solid particulate filler dispersed therein, wherein the filler has a surface area of 0.05 m2/g to 120 m2/g. The compositions may be formed into filaments for use in fused filament fabrication additive manufacturing. The filaments display good printability without drying or storage under dry conditions.

Abstract: A semi-crystalline blended polymer useful for additive manufacturing is comprised of an amorphous thermoplastic polymer and a thermoplastic semi-crystalline polymer, each of the polymers being essentially miscible in the other and being blended at a weight ratio of amorphous polymer/semi-crystalline polymer of greater that 1 to about 20. The semi-crystalline blended polymer displays a DSC melt peak enthalpy of at least about 3 joules/g. The semi-crystalline polymer may be made by blending the aforementioned polymers at the weight ratio and subject to heating between the melt temperature of the semi-crystalline polymer and the glass transition temperature of the amorphous polymer. The semi-crystalline blended polymer may revert to essentially an amorphous polymer when additive manufactured by fusing layers of said polymer powders together.

Abstract: Useful thermoplastic polymer powders are formed by a method comprising: cooling a foam comprised of a thermoplastic foam below the brittleness temperature of the thermoplastic polymer, wherein the foam has an average strut dimension of 10 to 500 micrometers, and comminuting the cooled foam to form a thermoplastic polymer powder. The method allows for the efficient grinding of the thermoplastic polymer having improved morphology and desirable characteristics such as dry flow without flow aids.

Abstract: A semicrystalline polyketone powder useful for additive manufacturing may be made by dissolving a polyketone having differential scanning calorimetry (DSC) monomodal melt peak, at a temperature above 50° C. to below the melt temperature of the polyketone, precipitating the dissolved polyketone by cooling, addition of a nonsolvent or combination thereof. The method may be used to form polyketones having a DSC melt peak with an enthalpy greater than the starting polyketone.

Abstract: In one instance a semicrystalline polyketone powder useful for additive manufacturing is comprised of a bimodal melt peak determined by an initial differential scanning calorimetry (DSC) scan at 20° C./min and a D90 particle size of at most 300 micrometers and average particle size of 1 micrometer to 150 micrometers equivalent spherical diameter. In another instance, A composition is comprised of a semicrystalline polyketone powder having a melt peak and a recrystallization peak, wherein the melt peak and recrystallization peak fail to overlap.

Abstract: An additive manufacturing composition useful as a support material for common build materials (e.g., polyamide or polyester) is comprised of a blend of an elastomer toughened styrenic polymer having discreet domains of polymerized conjugate diene dispersed within a styrenic matrix and a vinyl aromatic-maleic anhydride copolymer. The composition may be used as a support material in additive manufacturing methods such as extrusion methods (e.g., fused filament fabrication). The compositions may be tuned to realize the desired adherence to facilitate the desired support while also allowing for the mechanical removal without breakage of the underlying part or residual adhered support material.

Abstract: A composition useful for additive manufacturing is comprised of a thermoplastic elastomer blended with an aliphatic polyketone, wherein the thermoplastic elastomer is a continuous phase having dispersed therein separated domains of polyketone. The composition is useful for additive printing methods employing heating and extrusion of the composition to form extrudates that are printed an article comprised of fused layers of the composition. The composition facilitates the formation of extrusion based elastomeric additive manufactured articles.

Abstract: Included are a decorative floor or wall covering including a core and a core that can included recycled materials. This core includes a polyester comprising a polyester or copolyester derived from a reaction of a difunctional carboxylic acid and a difunctional hydroxyl compound; a polyolefin, at least one functionalized polymer comprising a compatibilizer, thermoplastic elastomer, impact modifier or coupling agent; and a filler.