Abstract: A particulate material useful for additive manufacturing contains a semicrystalline polycarbonate or a semicrystalline polyetherimide. The particles of the particulate material are characterized by a narrow volume-based distribution of equivalent spherical diameters in which the median equivalent spherical diameter (Dv50) M is in the range 35 to 85 micrometers, the equivalent spherical diameter corresponding to 1 percent of the cumulative undersize distribution (DvO1) is greater than 2 micrometers, and the equivalent spherical diameter corresponding to 99 percent of the cumulative undersize distribution (Dv99) is less than 115 micrometers. Also described is a method of additive manufacturing utilizing the particulate material.

Abstract: A semicrystalline polyphenylsulfone, has the structure Formula (I) wherein n and R are defined herein. The semicrystalline polyphenylsulfone, which exhibits a crystalline melting point in a range of 215 to 270° C., can be prepared from amorphous polyphenylsulfone using a solvent-induced crystallization method. An additive manufacturing method utilizing particles of the semicrystalline polyphenylsulfone is described.

Abstract: Provided are compositions including a population of particulates that comprise an at least partially crystalline polycarbonate having an average cross-sectional dimension of from about 1 to about 200 ?m, and have a weight-average molecular weight, per polystyrene standards, of from about 17,000 to about 40,000 Daltons. The composition exhibits a zero-shear viscosity of less than about 104 Pa·s at the melting temperature of the partially crystalline polycarbonate. Related systems and methods for utilizing these compositions in additive manufacturing applications, including selective laser sintering (SLS) applications, are also disclosed. Also provided are additively-manufactured articles made with the disclosed compositions and according to the disclosed methods.

Abstract: A particulate material useful for additive manufacturing contains a semicrystalline polycarbonate or a semicrystalline polyetherimide. The particles of the particulate material are characterized by a narrow volume-based distribution of equivalent spherical diameters in which the median equivalent spherical diameter (Dv50) M is in the range 35 to 85 micrometers, the equivalent spherical diameter corresponding to 1 percent of the cumulative undersize distribution (DvO1) is greater than 2 micrometers, and the equivalent spherical diameter corresponding to 99 percent of the cumulative undersize distribution (Dv99) is less than 115 micrometers. Also described is a method of additive manufacturing utilizing the particulate material.

Abstract: Provided are amorphous and at least partially crystalline polyetherimide compositions having a comparatively narrow particle size distribution and are particularly suited for additive manufacturing processes. The compositions comprise a population of polyetherimide particulates are characterized as having a zero-shear viscosity sufficiently low so as to achieve a coalescence of at least 0.5, and preferably of about 1.0, as characterized by the Frenkel model at a temperature less than 450° C.

Abstract: Provided are compositions including a population of particulates that comprise an at least partially crystalline polycarbonate having an average cross-sectional dimension of from about 1 to about 200 ?m, and have a weight-average molecular weight, per polystyrene standards, of from about 17,000 to about 40,000 Daltons. The composition exhibits a zero-shear viscosity of less than about 104 Pa·s at the melting temperature of the partially crystalline polycarbonate. Related systems and methods for utilizing these compositions in additive manufacturing applications, including selective laser sintering (SLS) applications, are also disclosed. Also provided are additively-manufactured articles made with the disclosed compositions and according to the disclosed methods.

Abstract: Provided are compositions comprising partially crystalline polycarbonate particulate having an average cross-sectional dimension of from about 1 ??? to about 200 ????, having from about 10% crystallinity to about 50% crystallinity, and having a weight-average molecular weight, per polystyrene standards, of from about 17,000 to about 40,000 Daltons. The composition exhibits a zero-shear viscosity of less than about 104 Pa s at the melting temperature of the partially crystalline polycarbonate. Related systems and methods for utilizing these compositions in additive manufacturing applications, including selective laser sintering (SLS) applications, are also disclosed. Also provided are additively-manufactured articles made with the disclosed compositions and according to the disclosed methods.

Abstract: Provided are thermoplastic-nanoparticle compositions that exhibit enhanced powder and melt flow. The disclosed compositions, comprising nanoparticles being silylated, have particular application in additive manufacturing processes, such as selective laser sintering and other processes.

Abstract: A semicrystalline polyphenylsulfone, has the structure Formula (I) wherein n and R are defined herein. The semicrystalline polyphenylsulfone, which exhibits a crystalline melting point in a range of 215 to 270° C., can be prepared from amorphous polyphenylsulfone using a solvent-induced crystallization method. An additive manufacturing method utilizing particles of the semicrystalline polyphenylsulfone is described.

Abstract: A composition for use in powder bed fusion includes a thermoplastic powder that itself includes an induced crystalline polycarbonate or an induced crystalline polyetherimide. The thermoplastic powder is recycled powder, which means that it is recovered from a powder bed that had undergone a powder bed fusion process. Also described is a method of making an article, the method including: placing an induced crystalline polymeric (polycarbonate or polyetherimide) powder in a powder bed, fusing a portion of the induced crystalline polymeric powder in the powder bed, recovering a least a portion of the crystalline polymeric powder from the powder bed, wherein the recovered powder is not fused, placing the recovered induced crystalline polymeric powder in a second powder bed, and fusing at least a portion of the recovered induced crystalline polymeric powder in the second powder bed to form an amorphous polymer article.

Abstract: Provided are particulate compositions that include a matrix polymer and fibrillated reinforcement materials (e.g., PTFE or ultra-high molecular weight polyethylene fibrils) dispersed therein. The compositions are suitable for use in additive manufacturing processes.

Abstract: A composition for use in powder bed fusion includes a thermoplastic powder that itself includes an induced crystalline polycarbonate or an induced crystalline polyetherimide. The thermoplastic powder is recycled powder, which means that it is recovered from a powder bed that had undergone a powder bed fusion process. Also described is a method of making an article, the method including: placing an induced crystalline polymeric (polycarbonate or polyetherimide) powder in a powder bed, fusing a portion of the induced crystalline polymeric powder in the powder bed, recovering a least a portion of the crystalline polymeric powder from the powder bed, wherein the recovered powder is not fused, placing the recovered induced crystalline polymeric powder in a second powder bed, and fusing at least a portion of the recovered induced crystalline polymeric powder in the second powder bed to form an amorphous polymer article.

Abstract: Provided are systems and methods for additive manufacturing, which systems and methods yield parts having improved interlayer adhesion. In the disclosed technology, additional heating steps are applied on the upper surface of the already printed workpiece so as to offset the dropping temperature of that surface during part fabrication. These heating steps elevate the temperature of the surface to a value that results in a molten interface with subsequently-applied build material, leading to improved interlayer adhesion. This technology is applicable to a variety of additive manufacturing processes, including but not limited to selective laser sintering, fused filament fabrication, and large format additive manufacturing approaches.

Abstract: Provided are amorphous and at least partially crystalline polyetherimide compositions having a comparatively narrow particle size distribution and are particularly suited for additive manufacturing processes. The compositions comprise a population of polyetherimide particulates are characterized as having a zero-shear viscosity sufficiently low so as to achieve a coalescence of at least 0.5, and preferably of about 1.0, as characterized by the Frenkel model at a temperature less than 450° C.

Abstract: Provided are compositions comprising partially crystalline polycarbonate particulate having an average cross-sectional dimension of from about 1 ??? to about 200 ????, having from about 10% crystallinity to about 50% crystallinity, and having a weight-average molecular weight, per polystyrene standards, of from about 17,000 to about 40,000 Daltons. The composition exhibits a zero-shear viscosity of less than about 104 Pa s at the melting temperature of the partially crystalline polycarbonate. Related systems and methods for utilizing these compositions in additive manufacturing applications, including selective laser sintering (SLS) applications, are also disclosed. Also provided are additively-manufactured articles made with the disclosed compositions and according to the disclosed methods.

Abstract: Provided are fibers that comprise a matrix thermoplastic polymer and fibrillated reinforcement materials (e.g., PTFE fibrils) dispersed therein. The disclosed fibers exhibit improved processability and other improved handling characteristics as compared to fibril-free fibers.

Abstract: Provided are thermoplastic-nanoparticle compositions that exhibit enhanced powder and melt flow. The disclosed compositions, comprising nanoparticles being silylated, have particular application in additive manufacturing processes, such as selective laser sintering and other processes.