Abstract: A method of 3D printing a part with an extrusion-based additive manufacturing system includes providing a filament having a semi-crystalline material as a majority component of a polymeric matrix to a liquefier having a liquefier tube having an overall length between an inlet end and an outlet end. An upper portion of the liquefier tube adjacent the inlet end has a first length and a first cross-sectional area substantially perpendicular to a longitudinal axis and a lower portion of the liquefier tube adjacent the outlet end has a second length and a second cross-sectional area substantially perpendicular to the longitudinal axis, wherein the first cross-sectional area is greater than the second cross-sectional area. The method includes driving the filament into a melt zone located within the upper portion of the liquefier tube at a selected rate based upon a desired extrusion rate. The filament is melted within the melt zone forming a melt pool in the liquefier tube to provide the selected extrusion rate.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi-crystalline polymers. The method also includes melting the part material in the additive manufacturing system, forming at least a portion of a layer of the three-dimensional part from the melted part material in a build environment, and maintaining the build environment at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi-crystalline polymers. The method also includes melting the part material in the additive manufacturing system, forming at least a portion of a layer of the three-dimensional part from the melted part material in a build environment, and maintaining the build environment at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.

Abstract: A consumable material configured for use in an additive manufacturing system includes a polymeric matrix having polyetherersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable for processing in the additive manufacturing system and having a Tg that is about 190° C. or greater and a coefficient of thermal expansion of less than about 30 ?m/(m·° C.). The consumable material is suitable for use in 3D printing of composite mold tools.

Abstract: A support material for use in an additive manufacturing system to print a support structure for a three-dimensional part. The support material includes a base resin that is substantially miscible with a part material used to print the three-dimensional part, and has a glass transition temperature within about 10° C. of a glass transition temperature of the part material. The support material also includes a dispersed resin that is substantially immiscible with the base resin, where the base resin and the dispersed resin are each thermally stable for use in the additive manufacturing system in coordination with the part material.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having at least a 3° C. reduction in a hot crystallization temperature relative to the neat semi-crystalline polymer.

Abstract: A method of 3D printing a part with an extrusion-based additive manufacturing system includes providing a filament having a semi-crystalline material as a majority component of a polymeric matrix to a liquefier having a liquefier tube having an overall length between an inlet end and an outlet end. An upper portion of the liquefier tube adjacent the inlet end has a first length and a first cross-sectional area substantially perpendicular to a longitudinal axis and a lower portion of the liquefier tube adjacent the outlet end has a second length and a second cross-sectional area substantially perpendicular to the longitudinal axis, wherein the first cross-sectional area is greater than the second cross-sectional area. The method includes driving the filament into a melt zone located within the upper portion of the liquefier tube at a selected rate based upon a desired extrusion rate. The filament is melted within the melt zone forming a melt pool in the liquefier tube to provide the selected extrusion rate.

Abstract: Part materials for additive manufacturing applications include materials with a fluoropolymer processing aid (material-FP). These materials include one or more thermoplastic polymers and one or more fluoropolymers as a processing aid. The material-FP is used to build parts with additive manufacturing systems. Parts built using material-FP have improved physical properties including improved strength in the z-direction of the parts. Composite systems such as reinforced filaments with the material-FP also have a higher density.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi-crystalline polymers. The method also includes melting the part material in the additive manufacturing system, forming at least a portion of a layer of the three-dimensional part from the melted part material in a build environment, and maintaining the build environment at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having at least a 3° C. reduction in a hot crystallization temperature relative to the neat semi-crystalline polymer.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system, which includes providing a part material that compositionally has one or more semi-crystalline polymers and one or more secondary materials that are configured to retard crystallization of the one or more semi-crystalline polymers, where the one or more secondary materials are substantially miscible with the one or more semi-crystalline polymers. The method also includes melting the part material in the additive manufacturing system, forming at least a portion of a layer of the three-dimensional part from the melted part material in a build environment, and maintaining the build environment at an annealing temperature that is between a glass transition temperature of the part material and a cold crystallization temperature of the part material.

Abstract: A support material for use in an additive manufacturing system to print a support structure for a three-dimensional part. The support material includes a base resin that is substantially miscible with a part material used to print the three-dimensional part, and has a glass transition temperature within about 10° C. of a glass transition temperature of the part material. The support material also includes a dispersed resin that is substantially immiscible with the base resin, where the base resin and the dispersed resin are each thermally stable for use in the additive manufacturing system in coordination with the part material.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having at least a 3° C. reduction in a hot crystallization temperature relative to the neat semi-crystalline polymer.

Abstract: A consumable material configured for use in an additive manufacturing system includes a polymeric matrix having polyetherersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable for processing in the additive manufacturing system and having a Tg that is about 190° C. or greater and a coefficient of thermal expansion of less than about 30 ?m/(m·° C.). The consumable material is suitable for use in 3D printing of composite mold tools.

Abstract: A support material for use in an additive manufacturing system to print a support structure for a three-dimensional part. The support material includes a base resin that is substantially miscible with a part material used to print the three-dimensional part, and has a glass transition temperature within about 10° C. of a glass transition temperature of the part material. The support material also includes a dispersed resin that is substantially immiscible with the base resin, where the base resin and the dispersed resin are each thermally stable for use in the additive manufacturing system in coordination with the part material.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.

Abstract: A method for printing a three-dimensional part with an additive manufacturing system includes providing a consumable feedstock material comprising a semi-crystalline polymer containing one or more secondary materials, wherein the consumable feedstock material has a process window in which crystalline kinetics are either accelerated or retarded. The consumable feedstock material is melted in the additive manufacturing system. At least a portion of the three-dimensional part from the melted consumable feedstock material in a build environment maintained within the process window.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.

Abstract: A polymeric material includes a semi-crystalline polymer and a secondary material wherein when the secondary material is combined with the semi-crystalline polymer to form a blend having an enthalpy that is between about 2 J/g heat of fusion and about 80% of the heat of fusion of the neat semi-crystalline material, as measured by differential scanning calorimetry (DSC) when cooling from a melting temperature to a hot crystalline temperature at a rate of 10° C./min.