Abstract: A sulfonated water-dispersible thermoplastic copolymer material for use as a support material in an additive manufacturing process is made by a method comprising providing a selected thermoplastic copolymer having an acid or an anhydride group; esterifying the acid group of the selected thermoplastic copolymer with a hydroxyl-functionalized sulfonate salt, or amidizing the acid group of the selected thermoplastic copolymer with an amine sulfonate salt, or imidizing the anhydride group of the selected thermoplastic copolymer with an amine sulfonate salt. The esterification, the amidization or the imidization results in a sulfonated water thermoplastic dispersible copolymer having a glass transition temperature suitable to provide an effective support during the additive manufacturing process and wherein the sulfonated water-dispersible thermoplastic copolymer will disperse in tap water in less than 1 hour.

Abstract: A filament for use in an extrusion-based additive manufacturing system includes an elastomeric core and a harder, non-elastomeric shell. The core compositionally comprising an elastomeric core material having a flexural modulus of less than 31,000 psi and a durometer of less than 80 Shore. The shell overlays the core portion and compositionally comprises a non-elastomeric thermoplastic shell material that is substantially miscible with the elastomeric core material, wherein the core material and the shell material have the same monomer chemistry. The non-elastomeric thermoplastic shell material has a flexural modulus that is greater than the flexural modulus of the elastomeric core material by at least a factor of five, wherein the shell provides sufficient strength or stiffness to the filament such that filament can be utilized as a feedstock in the extrusion-based additive manufacturing system.

Abstract: A water dispersible sulfo-polyamide is configured as a filament for use as an extrudable support material in the additive manufacture of a part comprising a non water dispersible polymer. The water dispersible sulfo-polyamide is a reaction product of a sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the part comprising the non water dispersible polymer.

Abstract: A method of processing a water-dispersible, polymer-based material in a bath of a water-based solution includes providing a molten water-dispersible polymer material having monovalent cations. The water-dispersible polymer is introduced into a water bath comprising multivalent salt dissociated in the water bath into multivalent cations and anions. The water-dispersible polymer is retained within the water bath with the dissociated multivalent cations to quench the water-dispersible, polymer-based material while the monovalent cations proximate a surface of the water-dispersible polymer are exchanged with multivalent cations to form a barrier that temporarily resists dispersion of the water-dispersible, polymer-based material within the water bath. The method includes removing the water-dispersible polymer from water bath after the exchange step.

Abstract: A water dispersible sulfopolymer for use as a material in the layer-wise additive manufacture of a 3D part made of a non water dispersible polymer wherein the water dispersible polymer is a reaction product of a metal sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the 3D part made of the non water dispersible polymer.

Abstract: A water-dispersible addition-type sulfonated thermoplastic copolymer material for use as a consumable feedstock additive manufacturing, wherein the water-dispersible thermoplastic copolymer is a reaction product of an addition-type reaction of a metal sulfonated monomer, the water-dispersible sulfonated thermoplastic copolymer being dispersible in tap water in less than one hour.

Abstract: A filament for use in an extrusion-based additive manufacturing system includes an elastomeric core and a harder, non-elastomeric shell. The core compositionally comprising an elastomeric core material having a flexural modulus of less than 31,000 psi and a durameter of less than 80 Shore. The shell overlays the core portion and compositionally comprises a non-elastomeric thermoplastic shell material that is substantially miscible with the elastomeric core material, wherein the core material and the shell material have the same monomer chemistry. The non-elastomeric thermoplastic shell material has a flexural modulus that is greater than the flexural modulus of the elastomeric core material by at least a factor of five, wherein the shell provides sufficient strength or stiffness to the filament such that filament can be utilized as a feedstock in the extrusion-based additive manufacturing system.

Abstract: A water dispersible sulfopolymer for use as a material in the layer-wise additive manufacture of a 3D part made of a non water dispersible polymer wherein the water dispersible polymer is a reaction product of a metal sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the 3D part made of the non water dispersible polymer.

Abstract: A sulfonated water-dispersible thermoplastic copolymer material for use as a support material in an additive manufacturing process is made by a method comprising providing a selected thermoplastic copolymer having an acid or an anhydride group; esterifying the acid group of the selected thermoplastic copolymer with a hydroxyl-functionalized sulfonate salt, or amidizing the acid group of the selected thermoplastic copolymer with an amine sulfonate salt, or imidizing the anhydride group of the selected thermoplastic copolymer with an amine sulfonate salt. The esterification, the amidization or the imidization results in a sulfonated water thermoplastic dispersible copolymer having a glass transition temperature suitable to provide an effective support during the additive manufacturing process and wherein the sulfonated water-dispersible thermoplastic copolymer will disperse in tap water in less than 1 hour.

Abstract: A method of recycling a water dispersible sulfonated polymer material used as a support structure in an additive manufacturing process includes providing a tap water bath and placing a printed part having an adhered support structure into the tap water bath, the support structure comprising a water-soluble sulfonated polymer material. The method includes dissolving the sulfonated polymer material in the water bath to thereby create a dispersion, and modifying the ionic strength of the dispersion by adding a multivalent metal salt to the dispersion at a concentration of between 1 gram/L and 30 grams/L, to precipitate the dissolved sulfonated polymer material from the water. The method includes recovering the precipitated sulfonated polymer material from the water, drying the recovered sulfonated polymer material and reforming the dried sulfonated polymer material into a form suitable for subsequent use as a consumable feedstock in an additive manufacturing process.

Abstract: A method of recycling and reusing a tap water-soluble sulfonated polymer material from a structural component made using an additive manufacturing process comprises dissolving the structural component in water to disperse the sulfonated polymer material into the water. The sulfonated polymer material is precipitated from the water and recovered; then dried and reformed into a form suitable for subsequent use as a consumable feedstock in a subsequent additive manufacturing process.

Abstract: A water dispersible sulfo-polyamide is configured as a filament for use as an extrudable support material in the additive manufacture of a part comprising a non water dispersible polymer. The water dispersible sulfo-polyamide is a reaction product of a sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the part comprising the non water dispersible polymer.

Abstract: A water dispersible sulfopolymer for use as a material in the layer-wise additive manufacture of a 3D part made of a non water dispersible polymer wherein the water dispersible polymer is a reaction product of a metal sulfo monomer, the water dispersible sulfo-polymer being dispersible in water resulting in separation of the water dispersible polymer from the 3D part made of the non water dispersible polymer.

Abstract: A method of recycling and reusing a tap water-soluble sulfonated polymer material from a structural component made using an additive manufacturing process comprises dissolving the structural component in water to disperse the sulfonated polymer material into the water. The sulfonated polymer material is precipitated from the water and recovered; then dried and reformed into a form suitable for subsequent use as a consumable feedstock in a subsequent additive manufacturing process.

Abstract: A support material feedstock comprising a first copolymer and a polymeric impact modifier, where the first copolymer includes a first monomer unit comprising a carboxyl group and a second monomer unit comprising a phenyl group.

Abstract: Disclosed is a method for smoothing the surface of an object built from a polymeric or wax material using a layered manufacturing rapid prototyping technique. After the object is built it is exposed to a vaporized solvent such as in a vaporizer for an exposure time sufficient to reflow the object surface. A solvent is chosen based on its ability to transiently soften the material which forms the object, and thereafter evaporate off the object. The object is removed from the solvent and allowed to dry, producing a smooth finished part.

Abstract: The present invention is a method (10) for manufacturing a three-dimensional object. The method (10) includes receiving (14) digital information of the three-dimensional object over a communication line and building (30) the three-dimensional object based at least in part on the received digital information, where at least part of the three-dimensional object is built by rapid manufacturing, and where the three-dimensional object comprises an exterior surface. The method also includes vapor smoothing (32) at least a portion of the exterior surface of the three-dimensional object.

Abstract: A method for building a three-dimensional object, the method comprising extruding a build material having a temperature profile between a surface and a central region of the extruded build material in which the surface has a higher temperature than the central region of the build material. The build material comprises a carrier material and nanofibers.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.

Abstract: The present invention is a composition for making a three-dimensional object. The composition comprises a plasticizer and a base polymer, where the base polymer comprises a carboxylic acid, where the composition is soluble in an alkaline solution.