Software Technology for “Compositions for additive manufacturing of objects”

3D Printing – Ludovic Gardet, Eastman Chemical Co

Abstract for “Compositions for additive manufacturing of objects”

“Filament comprising a polymeric material that includes a diacid component comprising from about 40 to 60 mole % of units derived from terephthalic acid and from about 40 to 60 mole % of units derived from a diacid chosen from isophthalic acid, a cyclohexanedicarboxylic acid, a naphthalenedicarboxylic acid, a stilbenedicarboxylic acid, or a combination thereof; a glycol component comprising at least 75 mole % of units derived from cyclohexanedimethanol; wherein the polymeric material has an inherent viscosity loss of 3% or less after being extruded; and method of using this filament in production of different articles by 3D printing are disclosed.”

Background for “Compositions for additive manufacturing of objects”

“Additive manufacturing uses electronic data to represent an object. This could be a computer-aided model (CAD) of the object. To form the object, the electronic data can be processed using a component of an additive manufacturing apparatus (e.g. a 3D printer). An electronic representation of an object can be mathematically divided into multiple horizontal layers. The contours of horizontal layers can be used to produce the object’s shape. The computing device component can create a build path for each horizontal layer, and send control signals back to the additive manufacturing apparatus’ extrusion section to move a nozzle down the build path in order to deposit a certain amount of the build material. Fluent strands are used to form horizontal layers. The build material is deposited layer by layer onto a platform. The additive manufacturing system can, for example, move the extrusion heads, build substrates, or both vertically and horizontally in order to form the object. To form a solid 3D object, the build material is hardened shortly after extrusion.

“The disclosure relates to compositions that can be used in an additive manufacturing process to produce objects.” These compositions can be made into filaments that are used in additive manufacturing to create an object.

An article may contain a number of layers of polymeric material, which can include units of a diacid and units of glycol components. A first and second acid can be used to derive the units of the diacid components. The article can be formed by depositing multiple layers of polymeric material onto a substrate. Sometimes, the plurality layers are deposited onto a substrate in accordance with a predetermined design.

An article may also include a body that contains units of a diacid and units of glycol components. The units of the diacid constituent are derived from one acid and another acid. The article’s body can be as small as 1 mm up to 5 mm in diameter and as long at least 3 cm in length. A process can be used to create the article. This involves combining a glycol and diacid component to make a polymeric material, and then extruding that polymeric material to create a filament.

“The present disclosure relates to techniques, systems and materials that allow objects to be produced using an additive manufacturing process. A predetermined design can be used to create an object by laying one or more layers on the substrate. This may include using three-dimensional (3D), model data. You can form the build material in the form of a filament. You can make a filament by adding a glycol and diacid components to create a polymeric materials and extruding it. In some cases, the polymeric material can include a co-polyester having units derived from cyclohexanedimethanol and units derived from terephthalic acid, isophthalic acid, cyclohexanedicarboxylic acid, naphthalenedicarboxylic acid, stilbenedicarboxylic acid, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or a combination thereof.”

The object created using the methods, systems, materials described herein can be used for any application, including modeling, rapid prototyping and production. The system used to create an object can be used in any context, including prosumer systems or professional-grade additive production systems. Extrusion-based 3D printers and materials to implement the techniques described herein, can be manufactured and sold to end-consumers for home building (e.g., DIY). 3D printing kits, desktop 3D Printers, packages that include the substrate (e.g. a polymeric sheet), for use with 3D printers and the like. A “package” is a group of items or components that are packaged for commercial sale. As used herein, a “package” is a group of items or components packaged for sale to consumers. They can be used as an additive manufacturing system or in conjunction with it. A package may include a filament made from a build material. A bundle package can also include components of an additive manufacturing device, such as a 3D Printer, build material filament and/or a substrate to be used in a 3D Printer to create objects. You can also include instructions in or on the package (e.g. printed text or slips of paper inside the package), which instructs the consumer how to use the contents.

“Additionally or alternatively, these materials and processes can be used to mass-produce objects with high throughput at additive production facilities. The following industries can benefit from the systems, techniques, and materials described in this document: Cosmetics (e.g. cosmetic container manufacturing), beverage container manufacture, product enclosure manufacturing, etc.

“The methods and systems described herein can produce polymeric materials that can then be used to create objects using additive manufacturing techniques. Polymeric materials may have properties that allow for the formation of filaments from them. The physical properties of the polymeric materials used in additive manufacturing can allow them to be extruded and rolled into filaments.

“The physical properties of polymeric materials may also be conducive to additive manufacturing processes. The polymeric materials may have a viscosity or melt stability at the temperatures used to make objects with additive manufacturing systems. The viscosity of the polymeric material described herein allows it to flow through an extrusionhead with little, if any, obstruction. The melt stability of polymeric materials reduces the risk of polymeric materials deteriorating at temperatures that are suitable for additive manufacturing.

“Polymeric materials may have physical properties that reduce shrinkage after extrusion, and can also be able to adhere with the substrate on which an object will be formed. A sufficient adhesion between the substrate, a build material and an object can reduce defects. There are many factors that can influence the choice of a substrate, build material, or additive manufacturing system. If a partially finished object doesn’t have enough adhesion to the substrate, it can move around and change its location on the substrate. The build material can then be placed in layers that cause the object’s shape to change from its intended form. Another example is that if there is not enough adhesion between the build material and the substrate, an object may become separated from the substrate, preventing it from being completed.

“Objects can also have defects that are caused due to adhesion between the substrate and the build material used to make them. The object can also cause damage to the substrate or the object. A physical object, tool, like a chisel, knife, or chemical process can be used to remove the object from the substrate. This may cause damage to the object/substrat, such that chips or flakes of material are separated from the substrate.

“The techniques and system described herein are possible to be implemented in many ways. Below are examples of implementations, with reference to these figures.

“The substrate can be placed on the platform106. The platform106 is designed to support the substrate104. The substrate 104 can then be placed on the platform 106 to act as a “working surface”. The substrate 104 can be used to build the object 102. In some cases, the substrate 104 may include a glass material. Other cases, the substrate can contain one or more polymeric material.

“System 100 can contain a housing 108 to house a variety of components from system 100. You can make the housing 108 from any number of materials such as metals or polymers or a combination thereof. An extrusion head 110 can be added to the system 100. An extrusion head 110 is able to extrude material onto the substrate (104), during the process of making the object 102. Any type of extrusion tip 110 is suitable for receiving material and extruding it through a nozzle (or tip). This nozzle or tip can have fluent strands, or roads? To form the object 102, the build material can be laid on the substrate 104 layer by layer. You can use nozzles with different sizes to deposit roads of build material that are different in thickness from the extrusion head 110.

The substrate 104 can be placed below the extrusion heads 110 during operation of the system 100 in the direction shown in FIG. 1. The first layer of build material is being deposited. You can place the substrate 104 at any distance below the extrusion heads 110. This will allow for fluent strands and roads to be deposited. to a desired thickness. The distance between the substrate (104) and the extrusion 110 before the first layer is deposited can vary from 0.02 to 4 mm in some cases. The extrusion head 110 can move in Z-direction increments as layers of the build materials are deposited to form object 102. This allows the deposit of a new layer at a specific thickness. The incremented distance may be as little as 0.1mm in some cases.

“The extrusionhead 110 can be attached to a horizontal rail 112. The horizontal rail 112 can be coupled to the extrusion head 110 so that it moves in the X direction. One or more stepper motors or servomotors can be used to move the extrusion head 110 along the horizontal rail 112. A first vertical rail (114) and a second rail (116) can be added to the system 100. Optionally, horizontal rail 112 may be connected to first vertical rail114 or second vertical rail116 so that horizontal rail 112 moves vertically in Z-direction with first vertical rail114 and second vertical rail116.

The extrusion head 110 is capable of moving along the horizontal rail 112 or the first vertical rail114, and the second vertical railroad 116 at speeds of at most about 5 mm/second to about 25 mm/second to about 50 mm/second to about 75 mm/second and at least 125 mm/second. The extrusion head 110 is also capable of moving along the horizontal rail 112 or the first vertical rail114, and the second verticalrail116 at speeds no higher than 400 mm/second. The extrusion head 110 is able to move along the horizontal and/or first vertical rails 114 and 116 at speeds ranging from about 2 mm/second up to 500 mm/second. Another example is that the extrusion heads 110 and/or the first and second vertical rails 114 and 116 can move at speeds ranging from about 20 mm/second up to 300 mm/second. An additional example is that the extrusion heads 110 can move along either the horizontal rail 112 or the first vertical rails 114 and 116 at speeds ranging from about 30 mm/second up to 100 mm/second.

“The system 100 may also contain a material source (118), which stores a build material to form objects with the system 100. A supply line 120 can connect the material source 118 to the extrusionhead 110. A material source 118 may include a material bay, or housing, containing a spool or filament of build material that can be pulled from the spool using a motor or drive unit. As an example, the supply line 120 can be turned off or on, and the build materials can be moved in either forward or backward directions. The build material can be retracted along the supply line 120 towards the material source 118 to reduce?drool. The extrusion head 110 can be controlled and/or the material source 118 can be withdrawn to minimize?drool. A drive unit, such as a worm drive, can control the speed at which build material is delivered to the extrusion heads 110.

The extrusion rate of the build material through the extrusionhead 110 should be no less than 3 mm3/s. It can also be no more than 3.5 mm3/s. At least 4 mm3/s. Minimum 5 mm3/s. Minimum about 6 mm3/s. Minimum about 10 mm3/s. Maximum about 50 mm3/s. Minimum about 100 mm3/s. Minimum about 200 mm3/s. Maximum about 500 mm3/s. Maximum about 1000 mm3/s. Minimum 2000 mm3/s. The extrusion rate at the extrusion head 110 must not exceed 10 mm3/s. It should not be greater that about 9.5mm3/s. It should not be greater than 9 mm3/s. It should not be greater than 8 mm3/s. It should also never exceed 7.5mm3/s. Or more than 7 mm3/s. An example of how the extrusion head 110 handles build material is from 2 to 3 mm3/s to 8400 mm3/s. An example of an extrusion rate where the build material flows through extrusion 110 is approximately 2 mm3/s to 12 mm3/s. Another example shows that the extrusion rate at the 110 extrusion head can range from approximately 4 mm3/s up to 10 mm3/s. An additional example illustrates how the build material flows through an extrusion head at an extrusion rate of about 7 mm3/s to 9 mm3/s. An example shows that the extrusion rate at the which the build material flows through an extrusion head can range from 7 mm3/s up to 8400 mm3/s. An example shows that the extrusion rate at the which the build material flows through an extrusion head can range from 100 mm3/s up to around 8400 mm3/s.

The build material that is stored at the material source 118 may contain a polymeric material. A thermoplastic polymer can be included in the build material, for example. A thermoplastic resin can be included in the build material, to illustrate. The build material may also include a polyester. The build material may also include a copolymer. A copolyester can also be included in the build material.

“Build material can contain units of an acid and glycol components. The units of an acid component can be obtained from one or several acids while the units for a glycol component can come from one or many particular glycols. The build material can contain 100 mole% of the acid and 100 mole% of glycol components. Sometimes, the acid component or part of the glycol can contain a branching agent. The acid component or glycol can contain at least 0.1 mole percent of a branching agents, but not more than 1.5 mole%. The branching agent can include one or more of trimellitic anhydride, trimellitic acid, pyromellitic dianhydride, trimesic acid, hemimellitic acid, glycerol, trimethylolpropane, pentaerythritol, 1,2,4-butanetriol, 1,2,6-hexanetriol, sorbitol, 1,1,4,4-tetrakis(hydroxymethy)cyclohexane, di pentaerythritol, or combinations thereof.”

“Acid components can contain units that are derived from one or several acids. Sometimes, the acid component may also include a diacid component. The acid component could include units of a primary acid and units for one or more secondary acids. The first acid may include terephthalic acids. In addition, the one or more second acids can be selected from a group of diacids including isophthalic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, a naphthalenedicarboxylic acid, a stilbenedicarboxylic acid, sebacic acid, dimethylmalonic acid, succinic acid, or combinations thereof. In some particular examples, the naphthalenedicarboxylic acid can include 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, or 2,7-naphthalenedicarboxylic acid.”

The acid component must contain at most 30 mole% units that were derived directly from the acid. It can also include units that are at least 35 mole% derived form the acid. The acid component must not exceed 75 mole% of units that were derived directly from the acid. It should also not include more than 70 mole% of units that were derived directly from acid. The acid component can contain units that were derived from the first acids in a range of 30 to 75 mole%. Another example shows that the acid component can contain anywhere from 35 to 65 mole% to approximately 65 mole% units derived form the first acid. An additional example shows that the acid component can contain anywhere from 40 to 60 mole% of units derived form the first acid. Another example is that the acid component can contain anywhere from 45 to 55 mole% units derived form the first acid.

The acid component must also include at most about 30 mole% units that were derived directly from one or two second acids. It can also contain at minimum about 35 mole% units that were derived indirectly from one or both second acids. The acid component must not exceed 75 mole% of units that were derived using the one-or more secondary acids. It should also not include more than 70 mole% units that were derived directly from the second acids. The acid component can contain units that are derived from one or more of the second acids in a range of about 30 to 75 mole%. Another example shows that the acid component can contain anywhere from 35 to 65 mole% to approximately 65 mole% units derived using the one or more secondary acids. An additional example shows that the acid component may include units derived from one or more second-acides at anywhere from 40 to 60 mole%. Another example is that the acid component may include units derived from one or more second chemicals. It can range from 45 to 55 mole%.

Further, the acid component may include units that are derived from additional acids such as additional dibasic acids with 4 to 40 carbons, additional dibasic acids with 4 to 40 carbons, additional dibasic acids with 4 to 40 carbons, additional cycloaliphatic acids having 4 or 40 carbons, additional aromatic dibasic acid having 4 to 40 carbons, and combinations of these acids. The acid component cannot contain more than 10 mole% units that were derived using one or several additional acids. It can also not include more than 8 mole% units that were derived by one or two additional acids. The acid component must contain at least 0.5 mole% units that are derived form one or several of the extra acids, at most about 1 mole% units derived by one or two of the additional acid, and at most about 2 mole% units derived primarily from one of the additional acid. An example of this is the acid component, which can contain units derived from any one or more additional acids.

The polymeric material can also be made from esters of acids. For example, the lower alkyl esters can be used to make the polymeric material. The polymeric material can be formed by methyl esters. In an illustrative example, esters of terephthalic acid, esters of isophthalic acid, esters of 1,3-cyclohexanedicarboxylic acid, esters of 1,4 cyclohexanedicarboxylic acid, esters of a naphthalenedicarboxylic acid, esters of a stilbenedicarboxylic acid, or combinations thereof, can be used to form the polymeric material.”

“The glycol component can include units derived from cyclohexanedimethanol. The polymeric material of a build material may contain multiple glycols. The glycol component may include units that are derived from a first and second glycols. To illustrate, the first glycol can include cyclohexanedimethanol and the one or more second glycols can include one or more glycols including about 2 to about 20 carbon atoms. One or more of the second glycols could include ethylene glycol or 1,2-propanediol or 1,3-propanediol and neopentyl glyol. The 1,5-pentanediol or 1,6-hexanediol or p-xylene glucol can also be used. In some cases, the build material can include polyethylene glycols, polytetramethylene glycols, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or a combination thereof.”

Optionally, units derived form multiple glycols can be included in the glycol components. This means that the glycol must contain at least 75 mole% units derived primarily from the initial glycol. At least 78 mole% units derived mainly from the original glycol. The glycol component cannot contain more than 98 mole% units that were derived form multiple glycols. It can also include units derived only from one glycol. The glycol component may include units derived form multiple glycols. This allows for the glycol to contain approximately 75 mole% to 98 mole% units derived directly from the first glycol. Another example is that the glycol components can contain units derived form multiple glycols. The glycol component can range from 85 mole% to 95 mole% units derived primarily from the first glycol.

“Furthermore the glycol components can not include units derived form multiple glycols. They must contain no more than 25 mole% units derived primarily from one or two second glycols. No more than 22 mole% units derived mainly from one or both second glycols. The glycol component cannot include more than 18 mole% units derived primarily from one or both second glycols. It also must not contain more than 15 mole% units derived primarily from one or other second glycols. If the glycol components include units that are derived form multiple glycols in some cases, the glycol can contain at most about 1 mole% of the units derived the one-or more second sugars, no greater than about 3 mole% of the units derived the one-or more second sugars, no greater than about 20 mole% of the units derived the one/more second glycols and at least 8 mole% of the units derived the one/more second glycols or at minimum about 10 mole% of the one/more second glycols or about 10 mole% of the one/more second derived units from the derived the one oder mehr als dies aus dem at the three mole percent of the units derived the one mole accountable for the units % of the units mole potentially them daring bei sometimes the one or Liege Geh an additional glycolin certain cases where the glycol glycol A simple example is that the glycol components can contain units derived form multiple glycols. The glycol component can range from approximately 2 mole% to 25 mole% of units derived the one or more secondary glycols. Another example is that the glycol components can contain units derived multiple glycols. The glycol component can have from 5 to 15 mole% to approximately 15 mole% units derived form the second glycols.

“In one particular example, the polymeric material of the build material can be comprised of an acid component including from about 48 mole % to about 55 mole % units derived from terephthalic acid and from about 44 mole % to about 52 mole % units derived from isophthalic acid and a glycol component including units derived from 1,4-cyclohexanedimethanol. In another particular example, the polymeric material can be comprised of an acid component including from about 47 mole % to about 53 mole % units derived from terephthalic acid and from about 47 mole % to about 53 mole % units derived from isophthalic acid and a glycol component including units derived from 1,4-cyclohexanedimethanol.”

The filament of the build material must have a diameter at minimum about 0.5mm, 1mm, 1.5mm or 2mm. The filament can also have a diameter of no more than 5 mm. It cannot be larger than 4 mm or 3 mm. Or 2.5 mm. The filament diameter can range from 0.3mm to 6mm in an illustration. Another example illustrates how the filament diameter can vary from 1 mm to 5 mm. Another example shows that the filament can have a diameter between 1.5mm and 3mm. The filament can also have a diameter of about 1.5 mm to 3 mm.

“The control system 122 can be included in system 100. One or more hardware processors and one or several physical memory devices can be included in the control system 122. One or more physical memories devices are examples of computer storage media that can store instructions. These instructions are executed by one or more processors to perform different functions. One or more physical memory can contain both volatile and non-volatile memories (e.g. RAM, ROM or the like). One or more of the physical memory devices may also include one, more, or all of the following: one, more buffers, one, more flash memory devices or a combination thereof. One or more components of the system 100 may also be included, such as input/output device. The system 100 could include, for example, a keyboard, mouse, touch screen, display, speakers and microphones. One or more communication interfaces can be included in the system 100 to exchange data with other devices via direct or network connections. The communication interfaces, for example, can be used to facilitate communications between a variety of networks and connections such as wired or wireless networks, or both.

“The control system 122 can be connected to or get data from a computer-aided designing (CAD) system in order to create a digital representation of object 102 that is to be created by system 100. To create the digital representation, 102 can be created using any CAD software program. A user may design an object with a specific shape and dimensions using a 3D modeling program that runs on a host machine. This object can then be manufactured using the system 100. The control system 122 is able to mathematically divide the digital representation of object 102 into multiple horizontal levels. This allows the user to convert the geometry of object 102 into computer-readable commands or instructions that can be used by a processor or controller for forming object 102. The control system 122 then can design build paths that will allow the build material to be placed in a layer by layer fashion to form object 102.

The control system 122 is capable of controlling and/or directing one or more of the components of the system 100. This includes the extrusion heads 110. It does this by controlling the movement of those components in accordance with a computer-controlled computer-aided manufacturing program. Optionally, control system 122 can direct one or more of the 100 components to move according to a script written in a programming languages such as Python. This script can be used for creating code in numerical programming languages such as Gcode that the control system can execute. You can use servo motors or microcontrollers to control the movement of various parts of the system 100 like the extrusion heads 110.

The control system 122 directs extrusion heads 110 to move along the horizontal rail 112 and/or vertical rails 112, 116 as build material is supplied. This allows the extrusionhead 110 to follow a predetermined build path, while depositing material for each layer of object 102. The rails 112,114,116 enable the extrusion heads 110 to move in a two-dimensional and/or three-dimensional manner in horizontal and/or vertical directions, as illustrated by the arrows in FIG. 1. Alternately, the platform 106 may be movable in either two-dimensions or three-dimensions. The control system 122 can control such relative movement to allow multiple roads of build materials to be deposited. To form each layer of object 102, move the extrusion 110 and/or platform 106 in a horizontal (2D) plane (X-Y plane). Next, move the extrusion 110 and/or platform 106 in a vertical, Z-direction.

“Optionally the substrate 104, build material from the material source 118 or a combination thereof can be included in a package which can be purchased and used with the system 100. Instructions on how to make objects with the filament of the build material can be included in the package. The instructions could include settings for system 100 such as the temperature at which to heat the filament of building material in the extrusion heads 110. These settings correspond to the composition of the filament.

“The object 102 may be created in a controlled environment. For example, individual components 100 can be confined to a chamber or another enclosure made by the housing 108. Temperature and other parameters can be controlled by temperature and pressure control elements. (e.g., heating elements, pumps, etc.). Sometimes, the temperature that is applied to the build materials can be set at or above the creep temperature. This allows for a slower cooling of the build material while it is being deposited onto substrate 104 to prevent warping of layers of object 102 after deposition.

“FIG. 2. illustrates components of an example second additive manufacturing system 200. The system 200 is identical to the one in FIG. 1. The system 200 is set up in a delta machine configuration. FIG. 2 does not show all components of system 200. 2 and details about some components of system 200 are shown in FIG. 2 because these features have already been described in FIG. 1.”

The system 200 may include an extrusionhead 202, which can be coupled to a first arms 204, 206 and 208. The first arm (204) can be movedably coupled with a first rail 220, while the second arm (206) can be movedably coupled with a second rail 212, and the third arm (208), can be movably connected to a third rail 214. The extrusion head 214, 206 and 208 can also be attached to the first arm, second, or third arms. The system 200 can also include a platform 215. A substrate 218 can optionally be placed on the platform 215. The substrate 218 can sometimes be removed from the platform 216.

The control system (not illustrated) can control the first, second, and third arms 204 to move the extrusion head 200 in such a way that it forms an object 220. The extrusion head can be moved according to predetermined designs by the first arm, second arm, and third arms 204. This allows for layers to be formed of object 220. A supply line 222 can feed the polymeric material that is used to make the object 220 to the extrusionhead 202. The supply line 222 can be used to feed a filament into an extrusion head 200 in order to make the object 220.

“FIG. 3. This is a side-view of multiple layers of object 300 that are deposited onto a substrate 302. As previously discussed with reference to FIG. As discussed previously with reference to FIG. FIG. 1 and FIG. 2. During the additive manufacturing process, which involves forming an object from a substrate, the build material can be supplied to an extrusionhead 304. The build material may also be heated. The build material is then placed on a surface using roads. FIG. 3 is an example. 3. The build material is directly deposited onto the substrate 302. The build material can also be placed directly onto the substrate 302. The first layer 306(1) is shown being deposited onto substrate 302, according to a predetermined building path. This can be a starting point for additive manufacturing. Multiple layers of build material can be added layer by layer to the substrate 302 as the extrusion head moves at a predetermined speed to form the object 300. The build material can be deposited to form layers 306(1)-306N. This will allow at least partial interfaces to be formed between the layers 306(1)-306N. An interface between the layers 306(1)-306(N) can be visible to the human eye, either with or without aid such as a microscope. An interface could be created between layers 306(1) or 306(2). Another example is the creation of an interface between layer 306(2) & layer 306(3). You can either have the object 300 formed 100% (i.e. a solid object) or less than 100% (at most, a portion of the object 300 that is partially hollow).

“The substrate 302 may include a glass material. The substrate 302 may also include a polymeric substance. The substrate 302 may include a coating of the corresponding polymeric material. The substrate 302 can also be made entirely of the polymeric materials. The substrate 302 could include a thermoplastic plastic polymer. A polyester can also be included in the substrate 302. The substrate 302 may also contain a glycol-modified, polyethylene terephthalate. A copolymer can also be included in the substrate 302. The substrate 302 may include a copolyester, as an example. The substrate 302 may also include an acrylonitrile-butadiene styrene copolymer or a phenolimide.

“The object 300’s build material can contain one or more polymeric substances. Any of the previously mentioned build materials with respect to the formation of the object 102 in FIG. can be used as one or more of the polymeric materials. 1. One example is that the build material for layers 306(1)-306 (N) of object 300 could contain a copolyester containing units of an acid and units of a glycer component.

Further, the density of the build material that is used to form layers 306(1)-306 (N) must be at least 0.8 g/cm3, 0.85 g/cm3, 0.9 g/cm3, 0.95 g/cm3, 0.95 g/cm3, 1.0 g/cm3, or 1.05 g/cm3. The build material that forms the layers 306(1)-306 (N) can be as low as 1.35 g/cm3, 1.30 g/cm3, 1.25 g/cm3, 1.25 g/cm3, 1.25 g/cm3, 1.25 g/cm3 or 1.05 g/cm3. It should not exceed about 1.35g/cm3, 1.25g/cm3, 1.25g/cm3, 1.25g/cm3, 1.25g/cm3, 1.15 g/cm3 or 1.1 g/cm3 or greater than 1.15 g/cm3 or greater than 1.15 g/cm3 and 1.15 g/cm3 or g/cm3. The build material that is used to form the layers 306(1)-306 (N) can range in density from 0.75 g/cm3 up to 1.4 g/cm3. Another example is that the build material used for the layers 306(1)-306 (N) can have a density of about 0.9 g/cm3 up to about 1.3g/cm3. A further example is that the build material used for the layers 306(1)-306 (N) can have a density of about 1.15 g/cm3- 1.25 g/cm3. You can measure the density using the American Society for Testing and Materials D 792 standard, as applicable to the date of filing this patent application.

“The build material used for the layers 306(1)-306 (N) can have a yield strength of at least 30 MPa. At least 35 MPa. At least 40 MPa. At least 45 MPa. Or at most 50 MPa. The tensile strength of the layer 306(1)-306 (N) build material can not exceed 80 MPa. It should not exceed about 75 MPa. It should not exceed about 65 MPa. It should not exceed about 60 MPa. And it shouldn’t exceed 55 MPa. The tensile strength of the material used to form layers 306(1)-306 (N) can range from 25 to 100 MPa. Another example is that the build material used for the layers 306(1)-306 (N) can have a yield of about 35 to 60 MPa. A further example is that the material used for the formation of the layers 306(1)-306 (N) can have a yield strength of about 45 to 55 MPa. At the time of filing this patent application, the ASTM D638 standard can be used to measure the tensile strength of yield.

The elongation of break for the layers 306(1)-306 (N) can be at least 80%, 95%, 110%, 125%, at most about 125%, at minimum about 140% or at most 155%. The elongation of break for the layers 306(1)-306 (N) can be no more than 230%, no higher than 215%, not greater than 200%, and no greater that 185% or no less than 170%. The elongation of break for the layers 306(1)-306N can range from 75% to 250%. Another example is that the build material used for the layers 306(1)-306 (N) can have an extension at break of about 95% to around 205%. Another example is that the build material used for the layers 306(1)-306 (N) can have an extension at break of about 80% to 120%. A further example is that the material used for the formation of the layers 306(1)-306 (N) can have an extension at break of approximately 180% to 220%. At the time of filing this patent application, the ASTM D638 standard can be used to measure the elongation of break.

“Additionally, the crystallization time for the build material that formed the layers 306(1)-306 (N) can be at least 80 minutes, at most about 90 minutes and at most about 100 minutes. At least 110 minutes, at minimum about 120 minutes or at the very least 130 minutes. The crystallization time for the layers 306(1)-306N can be no more than 1000 minutes, not greater than 500 minutes, not greater than 750 minutes or less than 400 minutes, and no longer than 300 minutes. It also doesn’t have to take more than 200 minutes. The crystallization time for the layers 306(1)-306N can range from 75 minutes to approximately 1000 minutes, as shown in the illustrative illustration. Another example is that the crystallization time for the layers 306(1)-306N can range from 100 minutes to 400 minutes. A further example is that the crystallization time for the layers 306(1)-306 (N) can range from 110 minutes to 180 minutes. You can measure the crystallization half-time using a small angle light scattering method using a helium neon light laser. This allows you to measure the time when the intensity of transmitted sunlight drops to half the maximum intensity while cooling the sample to a predetermined temperature.

The flexural modulus for the layers 306(1)-306 (N) must be at least 1700 MPa. At least 1750 MPa. At least 1800 MPa. Or at least 1900 MPa. The flexural modulus for the layers 306(1)-306 (N) is limited to no more than 2100 MPa. It can also not exceed about 2050 MPa. It cannot exceed about 2000 MPa or exceed about 50 MPa. The flexural modulus of the material used for the formation of the layers 306(1)-306 (N) can range from approximately 1700 to 2100 MPa. Another example is that the material used for the formation of the layers 306(1)-306 (N) may have a flexural modus ranging from 1775 MPa up to 1975 MPa. At the time of filing this patent application, the ASTM D790 standard can be used to determine the flexural modulus.

The thickness of the substrate 302 is 308 and the length is 310. The width of the substrate 302 can be perpendicular with its length 310. You can have the substrate 302 in any shape you like, such as square, rectangular, rectangular, triangular or any other suitable polygonal shape.

“The substrate 308’s thickness can be as low as 0.5mm, 1mm or 2mm. The thickness of the substrate 302 must not exceed 5 mm, 4 mm or 3 mm. An example of this is the thickness of the substrate 308 which can be included in the range of about 0.75 mm to approximately 4 mm. Another example shows that the thickness of the substrate 302 may be included in a range of approximately 1 mm to 2 mm.

The length 310 can be no more than 40 mm, 80 mm or 120 mm. Or at most 150 mm. The length 310 of substrate 302 must not exceed 500 mm. It should not exceed 400 mm. It should not exceed 300 mm. It should not exceed 250 mm. Or exceed 200 mm. The length 310 can be included in an illustration ranging from about 30 mm up to 600 mm. Another example is the length 310, which can be included in the substrate 302’s range of 40 mm to 250 mm. Another example is the length 310. This can be included in an area of 50 mm to 200 mm.

The substrate 302’s width can be as low as 35mm, 75mm, 125mm or 160mm. The substrate 302’s width cannot exceed 480mm, 390mm, or 310mm. It can also not exceed 250mm, 210mm, or 210mm. The width of the substrate 302 may be included in an illustration ranging from about 30 mm up to 600 mm. Another example shows that the width of the substrate 302. can be included in a range from 40 mm to approximately 250 mm. Another example shows that the width of the substrate 302. can be included in an area of 50 mm to 200 mm. A square-shaped substrate 302 may have a width between 100 and 200 mm, and a length of 312 from 100 to 200 mm.

“The thickness (in FIG. 3.) The thickness (in the Z-direction of FIG. Layers with a greater thickness can cause a more rigid or jagged object 300’s outer surface (i.e. a lower resolution object), while layers with lower thicknesses can make them less noticeable and the object 300 may have a smoother, more tactile outer surface (i.e. a higher resolution object). Each layer 306(1)-N can have a substantially uniform thickness or varying thickness.

A representative layer from the layers 306(1)-306 (N), such the layer 306?1, can have a thickness of 312 that ranges between about 5 and 2000 micrometers. The thickness of 312 can vary from 10 to 1000 micrometers in some cases. The thickness of 312 can also be between 25 and 500 micrometers. The thickness of 312 can range from 35 to 250 micrometers.

To provide adhesion between layers, the material of the substrate 302 is selected along with the build material of layers 306(1)-306 (N). The material of the substrate (302) and the material layer (306(1)) can be chosen to provide enough adhesion between the layers 302-306(N). This will ensure that the layer 306(1) is not removed from the substrate, but remains on substrate 302 during formation of object 300. You can also choose the material to build the layers 306(1)-306 (N) so that there is minimal movement between the substrate 302 and the layer 306(1). This will minimize or prevent any deformation of object 300.

“FIG. 4. This is a flow diagram showing an example 400 of the formation of an object on a substrate. It involves forming the object by depositing a plurality layers of polymeric material onto the substrate, and then removing it from the substrate. The 400-step process is represented as a series of blocks in a flow diagram. These blocks represent a sequence that can be executed, at least partially, by an additive manufacturing system using extrusions such as the 100 of FIG. 1. The additive manufacturing system 200 in FIG. 1, the additive manufacturing system 200 of FIG. 2, or both. The order of operations is not meant to be considered a limitation. Any number of blocks described can be combined in any order or in parallel to implement the process.

“A substrate 404 can also be provided at 402 for the formation of an object by an additive manufacturing process. The substrate 404 may be identical to or similar to substrate 104 in FIG. 1. The substrate 204 in FIG. 2, the substrate 204 of FIG. 3. Some examples of the providing substrate 404 at 402 may include mounting or attaching a preformed substrate404 to a platform such as FIG. 1. Another example is that the substrate 404 can be provided at 402 by using a suitable manufacturing method, such as injection molding, blow-molding or compression molding, casting, and any other suitable way to make the substrate 402.

A filament 406 can be made from a polymeric material that includes units of an acid and units of a glycer component. Sometimes, the filament 406 at 406 can be made by combining a glycol and a diacid component. One or more diacids or one or several glycols can be combined. The one or more diacids or one or two glycols may be mixed together in pellets, powder or some combination thereof. For example, the pellets of at most one diacid or glycol component can be ground before being combined. You can derive the units of an acid component from any number of acids, and the units for the glycol component from any number of glycols. One example is that the polymeric material can be made by combining one or more acids with one or several glycols.

“In certain cases, units can be derived from one or several dibasic acid components of the polymeric material. For example, the acid component can include units derived from a terephthalic acid, units derived from an isophthalic acid, units derived from a cyclohexanedicarboxylic acid, units derived from a naphthalene dicarboxylic acid, units derived from a stilbenedicarboxylic acid, or combinations thereof. The acid component can also be made up of about 40 to 60 mole% of units that are derived from an acid and about 40 to 60 mole% of units that are derived form a second acid. For example, units derived terephthalic acids can have the acid component comprised of between 45 and 55 mole% and about 45 to 55 mole% units derived terephthalic acids. Isophthalic acid can have the acid component comprised of approximately 45 to 55 mole% units.

“Additionally, the glycol component can include units derived from cyclohexamedimethanol. Further, the glycol component can include units derived from one or more additional glycols, such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, neopentyl glycol, 1,4-butanediol, 1,5-pentatnediol, 1,6-hexanediol, p-xylene glycol, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or combinations thereof. If the polymeric material contains units that are derived multiple glycols in some cases, the glycol can contain between 75 mole% and about 98 mole% units derived primarily from a first glycol. It can also include units derived from 2 to 4 Tetramethyl-1,3-cyclobutanediol or combinations thereof.

“The filament 408 polymeric material can contain additives such as stabilizers and antioxidants, fillers or branching agents, pigments or dyes, and combinations thereof.”

The polymeric material can then be combined with the glycol to make the filament 408. The polymeric material may be fed into an extruder in pellets or as a powder. The filament 408 can be made using either a single-screw extruder or a twin-screw extruder. Sometimes, an extruder may include a melt-pump, but in others, it can not. The speed of either a single or twin screw extruder can produce filament 408 at speeds ranging from 50 to 200 rotations per hour. The speed of the single or twin screw extruders can vary from 75 to 175 rotations per hour. Another example shows that the single or twin screw extruders can rotate at speeds of 60 to 85 rotations per minutes. The extruder can also feed one or more materials to form filament 408 at a rate of 10 grams/minute up to 40 grams/minute. It can also feed from 20 grams/minute up to 30 grams per hour, or 15 grams/minute up to 25 grams/minute.

The filament 408 can be as small as 1 mm up to 5 mm in diameter and as long at least 3 cm in length. The filament 408 may have a length of up to 5 cm in some cases. The filament 408 may have a length of 30 cm in some cases. The filament 408 may have a maximum length of about 3 cm to 5 m in some instances.

“In addition, when depositing the plurality layers of filament 408 onto substrate 404, the polymeric materials can be deposited at a specific rate. To produce the plurality layers of the object, the filament 408 may be extruded onto substrate 404. The ‘rate of extrusion’ is the rate at which filament 408 can be extruded onto the substrate 404 in these cases. The rate at which filament 408 is being deposited onto substrate 404 during formation of object 412 is an example. It can range from approximately 5.5 mm3/s up to approximately 9.5 mm3/s. Another example shows that the rate at which filament 408 is placed onto substrate 404 during formation of object 412 can range from approximately 6.5 mm3/s up to 9.0 mm3/s. Another illustration shows that the rate at which filament 408 is being deposited onto substrate 404 during formation of object 412 can range from 7.6 mm3/s up to 8.7 mm3/s.

“In some cases, object 412 may have a slight loss of intrinsic viscosity relative the inherent viscosity the polymeric material used in its production.” A loss of inherent viscosity with inherent viscosity is abbreviated I.V. The equation below can be described as:

The rate at which the filament 408’s polymeric material is deposited onto substrate 404 during formation of object 412 can also affect its inherent viscosity. The filament 408 may be deposited onto the substrate at a rate of about 7 mm3/s or 8 mm3/s during the formation of object 412. In this case, the inherent viscosity of the object 412 relative the polymeric material can be as low as about 5%, about 4.5%, about 3.5%, about 3.5%, about 2.5%, about 2.5%, about 1.5%, about 1.5%, about 0.9%, about 0.3% or 0.1%. The filament 408 can be deposited onto the substrate at a rate of about 7 mm3/s or 8 mm3/s during the formation process of the object 422. In these cases, the intrinsic viscosity of the object 412, relative to the filament 408, is minimal. An example of this is the filament 408 being deposited onto substrate 404 during formation of object 412. This can result in an intrinsic viscosity loss of approximately 0.01% to 6%. Another example shows that the intrinsic viscosity of the object 412 can vary from 0.7% to 4.3% relative to the filament 408. Another example is that the filament 408 is placed onto the substrate 408 during the formation process of the object 422. This can result in an inherent viscosity of the object 412, relative to the filament 408 at a rate of about 7 mm3/s or 8 mm3/s.

“In addition, the filament 408 must be deposited onto substrate 404 at a rate of about 8 mm3/s or about 9 mm3/s during the formation of object 412. The inherent viscosity of the object 412 relative the polymeric material can not exceed about 5%, about 4.5%, about 3.5%, about 3.5% and about 2.5% respectively. The filament 408 can be deposited onto the substrate at a rate of about 8 mm3/s or about 9 mm3/s during the formation process of the object 422. In these cases, the intrinsic viscosity of the object 422, relative to the filament 408, is minimal. An example of this is that the filament 408 can be deposited onto the substrate at a rate of about 8 mm3/s or about 9 mm3/s during the formation process of object 412. The inherent viscosity of the object 412 relative the polymeric material of filament 408 ranges from about 0.1% to 4.4%. Another example is that the filament 408 can be deposited onto the substrate 408 during the formation process of the object 422. This will result in an inherent viscosity loss between the filament 408 and the polymeric material 408. It can range from 0.1% to 3.3%. Another example is that the filament 408 can be deposited onto the substrate 408 during the formation process of object 412. This will result in an inherent viscosity of the object 412 relative the polymeric material. It can range from 0.2% to 0.9%.

“Inherent viscosity can be a sign of material degradation that occurs during additive manufacturing. A material’s mechanical properties can change if it loses its inherent viscosity. Sometimes, an object made using additive manufacturing processes can become brittle because of the loss in inherent viscosity.

“The object 412 can also have a notched Izod value ranging from 35 kJ/m2 up to 60 kJ/m2. Another example is the object 412. It can have a notched Izod value ranging from 40 kJ/m2 up to 55 kJ/m2. The object 412 may also have a notched Izod value ranging from 45 kJ/m2 up to 50 kJ/m2. At the time of filing this patent application, the notched Izod value of object 412 can also be measured using the ASTM D256 standard.

“At 414 the object 412 may be removed from substrate 404. A machine such as a robot arm can be used to remove object 412 from substrate 404. A hand-held tool or a pen can also be used to remove the object 412 form the substrate 404.

“Other architectures are possible to implement the described functionality and are included in this disclosure. For the purposes of discussion, specific distributions have been made of responsibilities. However, different functions and responsibilities may be divided and distributed depending on the circumstances.

“The following examples will further describe the concepts herein with reference to these figures. These figures do not limit disclosure as described in the claims.”

“EXAMPLES”

“Example 1”

“Samples were prepared of polymeric materials with the compositions shown in Table 1. Samples 1 through 2 were made according to the techniques described in this article. Samples 3 and 4, however, were used as comparisons. The components in Table 1 were not the only ones included in Sample 4. Sample 4 also contained a trimellitic andhydride branching agent. Proton nuclear magnetic resonance (NMR) was used to determine the composition of the samples.

“TABLE 1\nCompositions for Samples 1-4\nSample 1 Sample 2 Sample 3 Sample 4\nCyclohexanedimethanol 100 mole %? 31 mole% 31 mole% 31 mole% 31 mole% 31 mole% 31 mole%nEthylene Gellycol?0 mole% 69 mole %, 69 mole %, 69 mole% 69 mole% 69 mole% 69 %nTerephthalic acid 52 mole% 100 mole%? 100 mole% 100 mole%nIsophthalic acid 48 mole%?0 Mole%??0 Mole%?0 Mole%?0 Mole%?0 Mole%?”

“Some characteristics of the samples were measured using ASTM D standards. Table 2 shows the results of sample measurements.

Summary for “Compositions for additive manufacturing of objects”

“Additive manufacturing uses electronic data to represent an object. This could be a computer-aided model (CAD) of the object. To form the object, the electronic data can be processed using a component of an additive manufacturing apparatus (e.g. a 3D printer). An electronic representation of an object can be mathematically divided into multiple horizontal layers. The contours of horizontal layers can be used to produce the object’s shape. The computing device component can create a build path for each horizontal layer, and send control signals back to the additive manufacturing apparatus’ extrusion section to move a nozzle down the build path in order to deposit a certain amount of the build material. Fluent strands are used to form horizontal layers. The build material is deposited layer by layer onto a platform. The additive manufacturing system can, for example, move the extrusion heads, build substrates, or both vertically and horizontally in order to form the object. To form a solid 3D object, the build material is hardened shortly after extrusion.

“The disclosure relates to compositions that can be used in an additive manufacturing process to produce objects.” These compositions can be made into filaments that are used in additive manufacturing to create an object.

An article may contain a number of layers of polymeric material, which can include units of a diacid and units of glycol components. A first and second acid can be used to derive the units of the diacid components. The article can be formed by depositing multiple layers of polymeric material onto a substrate. Sometimes, the plurality layers are deposited onto a substrate in accordance with a predetermined design.

An article may also include a body that contains units of a diacid and units of glycol components. The units of the diacid constituent are derived from one acid and another acid. The article’s body can be as small as 1 mm up to 5 mm in diameter and as long at least 3 cm in length. A process can be used to create the article. This involves combining a glycol and diacid component to make a polymeric material, and then extruding that polymeric material to create a filament.

“The present disclosure relates to techniques, systems and materials that allow objects to be produced using an additive manufacturing process. A predetermined design can be used to create an object by laying one or more layers on the substrate. This may include using three-dimensional (3D), model data. You can form the build material in the form of a filament. You can make a filament by adding a glycol and diacid components to create a polymeric materials and extruding it. In some cases, the polymeric material can include a co-polyester having units derived from cyclohexanedimethanol and units derived from terephthalic acid, isophthalic acid, cyclohexanedicarboxylic acid, naphthalenedicarboxylic acid, stilbenedicarboxylic acid, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or a combination thereof.”

The object created using the methods, systems, materials described herein can be used for any application, including modeling, rapid prototyping and production. The system used to create an object can be used in any context, including prosumer systems or professional-grade additive production systems. Extrusion-based 3D printers and materials to implement the techniques described herein, can be manufactured and sold to end-consumers for home building (e.g., DIY). 3D printing kits, desktop 3D Printers, packages that include the substrate (e.g. a polymeric sheet), for use with 3D printers and the like. A “package” is a group of items or components that are packaged for commercial sale. As used herein, a “package” is a group of items or components packaged for sale to consumers. They can be used as an additive manufacturing system or in conjunction with it. A package may include a filament made from a build material. A bundle package can also include components of an additive manufacturing device, such as a 3D Printer, build material filament and/or a substrate to be used in a 3D Printer to create objects. You can also include instructions in or on the package (e.g. printed text or slips of paper inside the package), which instructs the consumer how to use the contents.

“Additionally or alternatively, these materials and processes can be used to mass-produce objects with high throughput at additive production facilities. The following industries can benefit from the systems, techniques, and materials described in this document: Cosmetics (e.g. cosmetic container manufacturing), beverage container manufacture, product enclosure manufacturing, etc.

“The methods and systems described herein can produce polymeric materials that can then be used to create objects using additive manufacturing techniques. Polymeric materials may have properties that allow for the formation of filaments from them. The physical properties of the polymeric materials used in additive manufacturing can allow them to be extruded and rolled into filaments.

“The physical properties of polymeric materials may also be conducive to additive manufacturing processes. The polymeric materials may have a viscosity or melt stability at the temperatures used to make objects with additive manufacturing systems. The viscosity of the polymeric material described herein allows it to flow through an extrusionhead with little, if any, obstruction. The melt stability of polymeric materials reduces the risk of polymeric materials deteriorating at temperatures that are suitable for additive manufacturing.

“Polymeric materials may have physical properties that reduce shrinkage after extrusion, and can also be able to adhere with the substrate on which an object will be formed. A sufficient adhesion between the substrate, a build material and an object can reduce defects. There are many factors that can influence the choice of a substrate, build material, or additive manufacturing system. If a partially finished object doesn’t have enough adhesion to the substrate, it can move around and change its location on the substrate. The build material can then be placed in layers that cause the object’s shape to change from its intended form. Another example is that if there is not enough adhesion between the build material and the substrate, an object may become separated from the substrate, preventing it from being completed.

“Objects can also have defects that are caused due to adhesion between the substrate and the build material used to make them. The object can also cause damage to the substrate or the object. A physical object, tool, like a chisel, knife, or chemical process can be used to remove the object from the substrate. This may cause damage to the object/substrat, such that chips or flakes of material are separated from the substrate.

“The techniques and system described herein are possible to be implemented in many ways. Below are examples of implementations, with reference to these figures.

“The substrate can be placed on the platform106. The platform106 is designed to support the substrate104. The substrate 104 can then be placed on the platform 106 to act as a “working surface”. The substrate 104 can be used to build the object 102. In some cases, the substrate 104 may include a glass material. Other cases, the substrate can contain one or more polymeric material.

“System 100 can contain a housing 108 to house a variety of components from system 100. You can make the housing 108 from any number of materials such as metals or polymers or a combination thereof. An extrusion head 110 can be added to the system 100. An extrusion head 110 is able to extrude material onto the substrate (104), during the process of making the object 102. Any type of extrusion tip 110 is suitable for receiving material and extruding it through a nozzle (or tip). This nozzle or tip can have fluent strands, or roads? To form the object 102, the build material can be laid on the substrate 104 layer by layer. You can use nozzles with different sizes to deposit roads of build material that are different in thickness from the extrusion head 110.

The substrate 104 can be placed below the extrusion heads 110 during operation of the system 100 in the direction shown in FIG. 1. The first layer of build material is being deposited. You can place the substrate 104 at any distance below the extrusion heads 110. This will allow for fluent strands and roads to be deposited. to a desired thickness. The distance between the substrate (104) and the extrusion 110 before the first layer is deposited can vary from 0.02 to 4 mm in some cases. The extrusion head 110 can move in Z-direction increments as layers of the build materials are deposited to form object 102. This allows the deposit of a new layer at a specific thickness. The incremented distance may be as little as 0.1mm in some cases.

“The extrusionhead 110 can be attached to a horizontal rail 112. The horizontal rail 112 can be coupled to the extrusion head 110 so that it moves in the X direction. One or more stepper motors or servomotors can be used to move the extrusion head 110 along the horizontal rail 112. A first vertical rail (114) and a second rail (116) can be added to the system 100. Optionally, horizontal rail 112 may be connected to first vertical rail114 or second vertical rail116 so that horizontal rail 112 moves vertically in Z-direction with first vertical rail114 and second vertical rail116.

The extrusion head 110 is capable of moving along the horizontal rail 112 or the first vertical rail114, and the second vertical railroad 116 at speeds of at most about 5 mm/second to about 25 mm/second to about 50 mm/second to about 75 mm/second and at least 125 mm/second. The extrusion head 110 is also capable of moving along the horizontal rail 112 or the first vertical rail114, and the second verticalrail116 at speeds no higher than 400 mm/second. The extrusion head 110 is able to move along the horizontal and/or first vertical rails 114 and 116 at speeds ranging from about 2 mm/second up to 500 mm/second. Another example is that the extrusion heads 110 and/or the first and second vertical rails 114 and 116 can move at speeds ranging from about 20 mm/second up to 300 mm/second. An additional example is that the extrusion heads 110 can move along either the horizontal rail 112 or the first vertical rails 114 and 116 at speeds ranging from about 30 mm/second up to 100 mm/second.

“The system 100 may also contain a material source (118), which stores a build material to form objects with the system 100. A supply line 120 can connect the material source 118 to the extrusionhead 110. A material source 118 may include a material bay, or housing, containing a spool or filament of build material that can be pulled from the spool using a motor or drive unit. As an example, the supply line 120 can be turned off or on, and the build materials can be moved in either forward or backward directions. The build material can be retracted along the supply line 120 towards the material source 118 to reduce?drool. The extrusion head 110 can be controlled and/or the material source 118 can be withdrawn to minimize?drool. A drive unit, such as a worm drive, can control the speed at which build material is delivered to the extrusion heads 110.

The extrusion rate of the build material through the extrusionhead 110 should be no less than 3 mm3/s. It can also be no more than 3.5 mm3/s. At least 4 mm3/s. Minimum 5 mm3/s. Minimum about 6 mm3/s. Minimum about 10 mm3/s. Maximum about 50 mm3/s. Minimum about 100 mm3/s. Minimum about 200 mm3/s. Maximum about 500 mm3/s. Maximum about 1000 mm3/s. Minimum 2000 mm3/s. The extrusion rate at the extrusion head 110 must not exceed 10 mm3/s. It should not be greater that about 9.5mm3/s. It should not be greater than 9 mm3/s. It should not be greater than 8 mm3/s. It should also never exceed 7.5mm3/s. Or more than 7 mm3/s. An example of how the extrusion head 110 handles build material is from 2 to 3 mm3/s to 8400 mm3/s. An example of an extrusion rate where the build material flows through extrusion 110 is approximately 2 mm3/s to 12 mm3/s. Another example shows that the extrusion rate at the 110 extrusion head can range from approximately 4 mm3/s up to 10 mm3/s. An additional example illustrates how the build material flows through an extrusion head at an extrusion rate of about 7 mm3/s to 9 mm3/s. An example shows that the extrusion rate at the which the build material flows through an extrusion head can range from 7 mm3/s up to 8400 mm3/s. An example shows that the extrusion rate at the which the build material flows through an extrusion head can range from 100 mm3/s up to around 8400 mm3/s.

The build material that is stored at the material source 118 may contain a polymeric material. A thermoplastic polymer can be included in the build material, for example. A thermoplastic resin can be included in the build material, to illustrate. The build material may also include a polyester. The build material may also include a copolymer. A copolyester can also be included in the build material.

“Build material can contain units of an acid and glycol components. The units of an acid component can be obtained from one or several acids while the units for a glycol component can come from one or many particular glycols. The build material can contain 100 mole% of the acid and 100 mole% of glycol components. Sometimes, the acid component or part of the glycol can contain a branching agent. The acid component or glycol can contain at least 0.1 mole percent of a branching agents, but not more than 1.5 mole%. The branching agent can include one or more of trimellitic anhydride, trimellitic acid, pyromellitic dianhydride, trimesic acid, hemimellitic acid, glycerol, trimethylolpropane, pentaerythritol, 1,2,4-butanetriol, 1,2,6-hexanetriol, sorbitol, 1,1,4,4-tetrakis(hydroxymethy)cyclohexane, di pentaerythritol, or combinations thereof.”

“Acid components can contain units that are derived from one or several acids. Sometimes, the acid component may also include a diacid component. The acid component could include units of a primary acid and units for one or more secondary acids. The first acid may include terephthalic acids. In addition, the one or more second acids can be selected from a group of diacids including isophthalic acid, 1,3-cyclohexanedicarboxylic acid, 1,4-cyclohexanedicarboxylic acid, a naphthalenedicarboxylic acid, a stilbenedicarboxylic acid, sebacic acid, dimethylmalonic acid, succinic acid, or combinations thereof. In some particular examples, the naphthalenedicarboxylic acid can include 1,4-naphthalenedicarboxylic acid, 1,5-naphthalenedicarboxylic acid, 2,6-naphthalenedicarboxylic acid, or 2,7-naphthalenedicarboxylic acid.”

The acid component must contain at most 30 mole% units that were derived directly from the acid. It can also include units that are at least 35 mole% derived form the acid. The acid component must not exceed 75 mole% of units that were derived directly from the acid. It should also not include more than 70 mole% of units that were derived directly from acid. The acid component can contain units that were derived from the first acids in a range of 30 to 75 mole%. Another example shows that the acid component can contain anywhere from 35 to 65 mole% to approximately 65 mole% units derived form the first acid. An additional example shows that the acid component can contain anywhere from 40 to 60 mole% of units derived form the first acid. Another example is that the acid component can contain anywhere from 45 to 55 mole% units derived form the first acid.

The acid component must also include at most about 30 mole% units that were derived directly from one or two second acids. It can also contain at minimum about 35 mole% units that were derived indirectly from one or both second acids. The acid component must not exceed 75 mole% of units that were derived using the one-or more secondary acids. It should also not include more than 70 mole% units that were derived directly from the second acids. The acid component can contain units that are derived from one or more of the second acids in a range of about 30 to 75 mole%. Another example shows that the acid component can contain anywhere from 35 to 65 mole% to approximately 65 mole% units derived using the one or more secondary acids. An additional example shows that the acid component may include units derived from one or more second-acides at anywhere from 40 to 60 mole%. Another example is that the acid component may include units derived from one or more second chemicals. It can range from 45 to 55 mole%.

Further, the acid component may include units that are derived from additional acids such as additional dibasic acids with 4 to 40 carbons, additional dibasic acids with 4 to 40 carbons, additional dibasic acids with 4 to 40 carbons, additional cycloaliphatic acids having 4 or 40 carbons, additional aromatic dibasic acid having 4 to 40 carbons, and combinations of these acids. The acid component cannot contain more than 10 mole% units that were derived using one or several additional acids. It can also not include more than 8 mole% units that were derived by one or two additional acids. The acid component must contain at least 0.5 mole% units that are derived form one or several of the extra acids, at most about 1 mole% units derived by one or two of the additional acid, and at most about 2 mole% units derived primarily from one of the additional acid. An example of this is the acid component, which can contain units derived from any one or more additional acids.

The polymeric material can also be made from esters of acids. For example, the lower alkyl esters can be used to make the polymeric material. The polymeric material can be formed by methyl esters. In an illustrative example, esters of terephthalic acid, esters of isophthalic acid, esters of 1,3-cyclohexanedicarboxylic acid, esters of 1,4 cyclohexanedicarboxylic acid, esters of a naphthalenedicarboxylic acid, esters of a stilbenedicarboxylic acid, or combinations thereof, can be used to form the polymeric material.”

“The glycol component can include units derived from cyclohexanedimethanol. The polymeric material of a build material may contain multiple glycols. The glycol component may include units that are derived from a first and second glycols. To illustrate, the first glycol can include cyclohexanedimethanol and the one or more second glycols can include one or more glycols including about 2 to about 20 carbon atoms. One or more of the second glycols could include ethylene glycol or 1,2-propanediol or 1,3-propanediol and neopentyl glyol. The 1,5-pentanediol or 1,6-hexanediol or p-xylene glucol can also be used. In some cases, the build material can include polyethylene glycols, polytetramethylene glycols, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or a combination thereof.”

Optionally, units derived form multiple glycols can be included in the glycol components. This means that the glycol must contain at least 75 mole% units derived primarily from the initial glycol. At least 78 mole% units derived mainly from the original glycol. The glycol component cannot contain more than 98 mole% units that were derived form multiple glycols. It can also include units derived only from one glycol. The glycol component may include units derived form multiple glycols. This allows for the glycol to contain approximately 75 mole% to 98 mole% units derived directly from the first glycol. Another example is that the glycol components can contain units derived form multiple glycols. The glycol component can range from 85 mole% to 95 mole% units derived primarily from the first glycol.

“Furthermore the glycol components can not include units derived form multiple glycols. They must contain no more than 25 mole% units derived primarily from one or two second glycols. No more than 22 mole% units derived mainly from one or both second glycols. The glycol component cannot include more than 18 mole% units derived primarily from one or both second glycols. It also must not contain more than 15 mole% units derived primarily from one or other second glycols. If the glycol components include units that are derived form multiple glycols in some cases, the glycol can contain at most about 1 mole% of the units derived the one-or more second sugars, no greater than about 3 mole% of the units derived the one-or more second sugars, no greater than about 20 mole% of the units derived the one/more second glycols and at least 8 mole% of the units derived the one/more second glycols or at minimum about 10 mole% of the one/more second glycols or about 10 mole% of the one/more second derived units from the derived the one oder mehr als dies aus dem at the three mole percent of the units derived the one mole accountable for the units % of the units mole potentially them daring bei sometimes the one or Liege Geh an additional glycolin certain cases where the glycol glycol A simple example is that the glycol components can contain units derived form multiple glycols. The glycol component can range from approximately 2 mole% to 25 mole% of units derived the one or more secondary glycols. Another example is that the glycol components can contain units derived multiple glycols. The glycol component can have from 5 to 15 mole% to approximately 15 mole% units derived form the second glycols.

“In one particular example, the polymeric material of the build material can be comprised of an acid component including from about 48 mole % to about 55 mole % units derived from terephthalic acid and from about 44 mole % to about 52 mole % units derived from isophthalic acid and a glycol component including units derived from 1,4-cyclohexanedimethanol. In another particular example, the polymeric material can be comprised of an acid component including from about 47 mole % to about 53 mole % units derived from terephthalic acid and from about 47 mole % to about 53 mole % units derived from isophthalic acid and a glycol component including units derived from 1,4-cyclohexanedimethanol.”

The filament of the build material must have a diameter at minimum about 0.5mm, 1mm, 1.5mm or 2mm. The filament can also have a diameter of no more than 5 mm. It cannot be larger than 4 mm or 3 mm. Or 2.5 mm. The filament diameter can range from 0.3mm to 6mm in an illustration. Another example illustrates how the filament diameter can vary from 1 mm to 5 mm. Another example shows that the filament can have a diameter between 1.5mm and 3mm. The filament can also have a diameter of about 1.5 mm to 3 mm.

“The control system 122 can be included in system 100. One or more hardware processors and one or several physical memory devices can be included in the control system 122. One or more physical memories devices are examples of computer storage media that can store instructions. These instructions are executed by one or more processors to perform different functions. One or more physical memory can contain both volatile and non-volatile memories (e.g. RAM, ROM or the like). One or more of the physical memory devices may also include one, more, or all of the following: one, more buffers, one, more flash memory devices or a combination thereof. One or more components of the system 100 may also be included, such as input/output device. The system 100 could include, for example, a keyboard, mouse, touch screen, display, speakers and microphones. One or more communication interfaces can be included in the system 100 to exchange data with other devices via direct or network connections. The communication interfaces, for example, can be used to facilitate communications between a variety of networks and connections such as wired or wireless networks, or both.

“The control system 122 can be connected to or get data from a computer-aided designing (CAD) system in order to create a digital representation of object 102 that is to be created by system 100. To create the digital representation, 102 can be created using any CAD software program. A user may design an object with a specific shape and dimensions using a 3D modeling program that runs on a host machine. This object can then be manufactured using the system 100. The control system 122 is able to mathematically divide the digital representation of object 102 into multiple horizontal levels. This allows the user to convert the geometry of object 102 into computer-readable commands or instructions that can be used by a processor or controller for forming object 102. The control system 122 then can design build paths that will allow the build material to be placed in a layer by layer fashion to form object 102.

The control system 122 is capable of controlling and/or directing one or more of the components of the system 100. This includes the extrusion heads 110. It does this by controlling the movement of those components in accordance with a computer-controlled computer-aided manufacturing program. Optionally, control system 122 can direct one or more of the 100 components to move according to a script written in a programming languages such as Python. This script can be used for creating code in numerical programming languages such as Gcode that the control system can execute. You can use servo motors or microcontrollers to control the movement of various parts of the system 100 like the extrusion heads 110.

The control system 122 directs extrusion heads 110 to move along the horizontal rail 112 and/or vertical rails 112, 116 as build material is supplied. This allows the extrusionhead 110 to follow a predetermined build path, while depositing material for each layer of object 102. The rails 112,114,116 enable the extrusion heads 110 to move in a two-dimensional and/or three-dimensional manner in horizontal and/or vertical directions, as illustrated by the arrows in FIG. 1. Alternately, the platform 106 may be movable in either two-dimensions or three-dimensions. The control system 122 can control such relative movement to allow multiple roads of build materials to be deposited. To form each layer of object 102, move the extrusion 110 and/or platform 106 in a horizontal (2D) plane (X-Y plane). Next, move the extrusion 110 and/or platform 106 in a vertical, Z-direction.

“Optionally the substrate 104, build material from the material source 118 or a combination thereof can be included in a package which can be purchased and used with the system 100. Instructions on how to make objects with the filament of the build material can be included in the package. The instructions could include settings for system 100 such as the temperature at which to heat the filament of building material in the extrusion heads 110. These settings correspond to the composition of the filament.

“The object 102 may be created in a controlled environment. For example, individual components 100 can be confined to a chamber or another enclosure made by the housing 108. Temperature and other parameters can be controlled by temperature and pressure control elements. (e.g., heating elements, pumps, etc.). Sometimes, the temperature that is applied to the build materials can be set at or above the creep temperature. This allows for a slower cooling of the build material while it is being deposited onto substrate 104 to prevent warping of layers of object 102 after deposition.

“FIG. 2. illustrates components of an example second additive manufacturing system 200. The system 200 is identical to the one in FIG. 1. The system 200 is set up in a delta machine configuration. FIG. 2 does not show all components of system 200. 2 and details about some components of system 200 are shown in FIG. 2 because these features have already been described in FIG. 1.”

The system 200 may include an extrusionhead 202, which can be coupled to a first arms 204, 206 and 208. The first arm (204) can be movedably coupled with a first rail 220, while the second arm (206) can be movedably coupled with a second rail 212, and the third arm (208), can be movably connected to a third rail 214. The extrusion head 214, 206 and 208 can also be attached to the first arm, second, or third arms. The system 200 can also include a platform 215. A substrate 218 can optionally be placed on the platform 215. The substrate 218 can sometimes be removed from the platform 216.

The control system (not illustrated) can control the first, second, and third arms 204 to move the extrusion head 200 in such a way that it forms an object 220. The extrusion head can be moved according to predetermined designs by the first arm, second arm, and third arms 204. This allows for layers to be formed of object 220. A supply line 222 can feed the polymeric material that is used to make the object 220 to the extrusionhead 202. The supply line 222 can be used to feed a filament into an extrusion head 200 in order to make the object 220.

“FIG. 3. This is a side-view of multiple layers of object 300 that are deposited onto a substrate 302. As previously discussed with reference to FIG. As discussed previously with reference to FIG. FIG. 1 and FIG. 2. During the additive manufacturing process, which involves forming an object from a substrate, the build material can be supplied to an extrusionhead 304. The build material may also be heated. The build material is then placed on a surface using roads. FIG. 3 is an example. 3. The build material is directly deposited onto the substrate 302. The build material can also be placed directly onto the substrate 302. The first layer 306(1) is shown being deposited onto substrate 302, according to a predetermined building path. This can be a starting point for additive manufacturing. Multiple layers of build material can be added layer by layer to the substrate 302 as the extrusion head moves at a predetermined speed to form the object 300. The build material can be deposited to form layers 306(1)-306N. This will allow at least partial interfaces to be formed between the layers 306(1)-306N. An interface between the layers 306(1)-306(N) can be visible to the human eye, either with or without aid such as a microscope. An interface could be created between layers 306(1) or 306(2). Another example is the creation of an interface between layer 306(2) & layer 306(3). You can either have the object 300 formed 100% (i.e. a solid object) or less than 100% (at most, a portion of the object 300 that is partially hollow).

“The substrate 302 may include a glass material. The substrate 302 may also include a polymeric substance. The substrate 302 may include a coating of the corresponding polymeric material. The substrate 302 can also be made entirely of the polymeric materials. The substrate 302 could include a thermoplastic plastic polymer. A polyester can also be included in the substrate 302. The substrate 302 may also contain a glycol-modified, polyethylene terephthalate. A copolymer can also be included in the substrate 302. The substrate 302 may include a copolyester, as an example. The substrate 302 may also include an acrylonitrile-butadiene styrene copolymer or a phenolimide.

“The object 300’s build material can contain one or more polymeric substances. Any of the previously mentioned build materials with respect to the formation of the object 102 in FIG. can be used as one or more of the polymeric materials. 1. One example is that the build material for layers 306(1)-306 (N) of object 300 could contain a copolyester containing units of an acid and units of a glycer component.

Further, the density of the build material that is used to form layers 306(1)-306 (N) must be at least 0.8 g/cm3, 0.85 g/cm3, 0.9 g/cm3, 0.95 g/cm3, 0.95 g/cm3, 1.0 g/cm3, or 1.05 g/cm3. The build material that forms the layers 306(1)-306 (N) can be as low as 1.35 g/cm3, 1.30 g/cm3, 1.25 g/cm3, 1.25 g/cm3, 1.25 g/cm3, 1.25 g/cm3 or 1.05 g/cm3. It should not exceed about 1.35g/cm3, 1.25g/cm3, 1.25g/cm3, 1.25g/cm3, 1.25g/cm3, 1.15 g/cm3 or 1.1 g/cm3 or greater than 1.15 g/cm3 or greater than 1.15 g/cm3 and 1.15 g/cm3 or g/cm3. The build material that is used to form the layers 306(1)-306 (N) can range in density from 0.75 g/cm3 up to 1.4 g/cm3. Another example is that the build material used for the layers 306(1)-306 (N) can have a density of about 0.9 g/cm3 up to about 1.3g/cm3. A further example is that the build material used for the layers 306(1)-306 (N) can have a density of about 1.15 g/cm3- 1.25 g/cm3. You can measure the density using the American Society for Testing and Materials D 792 standard, as applicable to the date of filing this patent application.

“The build material used for the layers 306(1)-306 (N) can have a yield strength of at least 30 MPa. At least 35 MPa. At least 40 MPa. At least 45 MPa. Or at most 50 MPa. The tensile strength of the layer 306(1)-306 (N) build material can not exceed 80 MPa. It should not exceed about 75 MPa. It should not exceed about 65 MPa. It should not exceed about 60 MPa. And it shouldn’t exceed 55 MPa. The tensile strength of the material used to form layers 306(1)-306 (N) can range from 25 to 100 MPa. Another example is that the build material used for the layers 306(1)-306 (N) can have a yield of about 35 to 60 MPa. A further example is that the material used for the formation of the layers 306(1)-306 (N) can have a yield strength of about 45 to 55 MPa. At the time of filing this patent application, the ASTM D638 standard can be used to measure the tensile strength of yield.

The elongation of break for the layers 306(1)-306 (N) can be at least 80%, 95%, 110%, 125%, at most about 125%, at minimum about 140% or at most 155%. The elongation of break for the layers 306(1)-306 (N) can be no more than 230%, no higher than 215%, not greater than 200%, and no greater that 185% or no less than 170%. The elongation of break for the layers 306(1)-306N can range from 75% to 250%. Another example is that the build material used for the layers 306(1)-306 (N) can have an extension at break of about 95% to around 205%. Another example is that the build material used for the layers 306(1)-306 (N) can have an extension at break of about 80% to 120%. A further example is that the material used for the formation of the layers 306(1)-306 (N) can have an extension at break of approximately 180% to 220%. At the time of filing this patent application, the ASTM D638 standard can be used to measure the elongation of break.

“Additionally, the crystallization time for the build material that formed the layers 306(1)-306 (N) can be at least 80 minutes, at most about 90 minutes and at most about 100 minutes. At least 110 minutes, at minimum about 120 minutes or at the very least 130 minutes. The crystallization time for the layers 306(1)-306N can be no more than 1000 minutes, not greater than 500 minutes, not greater than 750 minutes or less than 400 minutes, and no longer than 300 minutes. It also doesn’t have to take more than 200 minutes. The crystallization time for the layers 306(1)-306N can range from 75 minutes to approximately 1000 minutes, as shown in the illustrative illustration. Another example is that the crystallization time for the layers 306(1)-306N can range from 100 minutes to 400 minutes. A further example is that the crystallization time for the layers 306(1)-306 (N) can range from 110 minutes to 180 minutes. You can measure the crystallization half-time using a small angle light scattering method using a helium neon light laser. This allows you to measure the time when the intensity of transmitted sunlight drops to half the maximum intensity while cooling the sample to a predetermined temperature.

The flexural modulus for the layers 306(1)-306 (N) must be at least 1700 MPa. At least 1750 MPa. At least 1800 MPa. Or at least 1900 MPa. The flexural modulus for the layers 306(1)-306 (N) is limited to no more than 2100 MPa. It can also not exceed about 2050 MPa. It cannot exceed about 2000 MPa or exceed about 50 MPa. The flexural modulus of the material used for the formation of the layers 306(1)-306 (N) can range from approximately 1700 to 2100 MPa. Another example is that the material used for the formation of the layers 306(1)-306 (N) may have a flexural modus ranging from 1775 MPa up to 1975 MPa. At the time of filing this patent application, the ASTM D790 standard can be used to determine the flexural modulus.

The thickness of the substrate 302 is 308 and the length is 310. The width of the substrate 302 can be perpendicular with its length 310. You can have the substrate 302 in any shape you like, such as square, rectangular, rectangular, triangular or any other suitable polygonal shape.

“The substrate 308’s thickness can be as low as 0.5mm, 1mm or 2mm. The thickness of the substrate 302 must not exceed 5 mm, 4 mm or 3 mm. An example of this is the thickness of the substrate 308 which can be included in the range of about 0.75 mm to approximately 4 mm. Another example shows that the thickness of the substrate 302 may be included in a range of approximately 1 mm to 2 mm.

The length 310 can be no more than 40 mm, 80 mm or 120 mm. Or at most 150 mm. The length 310 of substrate 302 must not exceed 500 mm. It should not exceed 400 mm. It should not exceed 300 mm. It should not exceed 250 mm. Or exceed 200 mm. The length 310 can be included in an illustration ranging from about 30 mm up to 600 mm. Another example is the length 310, which can be included in the substrate 302’s range of 40 mm to 250 mm. Another example is the length 310. This can be included in an area of 50 mm to 200 mm.

The substrate 302’s width can be as low as 35mm, 75mm, 125mm or 160mm. The substrate 302’s width cannot exceed 480mm, 390mm, or 310mm. It can also not exceed 250mm, 210mm, or 210mm. The width of the substrate 302 may be included in an illustration ranging from about 30 mm up to 600 mm. Another example shows that the width of the substrate 302. can be included in a range from 40 mm to approximately 250 mm. Another example shows that the width of the substrate 302. can be included in an area of 50 mm to 200 mm. A square-shaped substrate 302 may have a width between 100 and 200 mm, and a length of 312 from 100 to 200 mm.

“The thickness (in FIG. 3.) The thickness (in the Z-direction of FIG. Layers with a greater thickness can cause a more rigid or jagged object 300’s outer surface (i.e. a lower resolution object), while layers with lower thicknesses can make them less noticeable and the object 300 may have a smoother, more tactile outer surface (i.e. a higher resolution object). Each layer 306(1)-N can have a substantially uniform thickness or varying thickness.

A representative layer from the layers 306(1)-306 (N), such the layer 306?1, can have a thickness of 312 that ranges between about 5 and 2000 micrometers. The thickness of 312 can vary from 10 to 1000 micrometers in some cases. The thickness of 312 can also be between 25 and 500 micrometers. The thickness of 312 can range from 35 to 250 micrometers.

To provide adhesion between layers, the material of the substrate 302 is selected along with the build material of layers 306(1)-306 (N). The material of the substrate (302) and the material layer (306(1)) can be chosen to provide enough adhesion between the layers 302-306(N). This will ensure that the layer 306(1) is not removed from the substrate, but remains on substrate 302 during formation of object 300. You can also choose the material to build the layers 306(1)-306 (N) so that there is minimal movement between the substrate 302 and the layer 306(1). This will minimize or prevent any deformation of object 300.

“FIG. 4. This is a flow diagram showing an example 400 of the formation of an object on a substrate. It involves forming the object by depositing a plurality layers of polymeric material onto the substrate, and then removing it from the substrate. The 400-step process is represented as a series of blocks in a flow diagram. These blocks represent a sequence that can be executed, at least partially, by an additive manufacturing system using extrusions such as the 100 of FIG. 1. The additive manufacturing system 200 in FIG. 1, the additive manufacturing system 200 of FIG. 2, or both. The order of operations is not meant to be considered a limitation. Any number of blocks described can be combined in any order or in parallel to implement the process.

“A substrate 404 can also be provided at 402 for the formation of an object by an additive manufacturing process. The substrate 404 may be identical to or similar to substrate 104 in FIG. 1. The substrate 204 in FIG. 2, the substrate 204 of FIG. 3. Some examples of the providing substrate 404 at 402 may include mounting or attaching a preformed substrate404 to a platform such as FIG. 1. Another example is that the substrate 404 can be provided at 402 by using a suitable manufacturing method, such as injection molding, blow-molding or compression molding, casting, and any other suitable way to make the substrate 402.

A filament 406 can be made from a polymeric material that includes units of an acid and units of a glycer component. Sometimes, the filament 406 at 406 can be made by combining a glycol and a diacid component. One or more diacids or one or several glycols can be combined. The one or more diacids or one or two glycols may be mixed together in pellets, powder or some combination thereof. For example, the pellets of at most one diacid or glycol component can be ground before being combined. You can derive the units of an acid component from any number of acids, and the units for the glycol component from any number of glycols. One example is that the polymeric material can be made by combining one or more acids with one or several glycols.

“In certain cases, units can be derived from one or several dibasic acid components of the polymeric material. For example, the acid component can include units derived from a terephthalic acid, units derived from an isophthalic acid, units derived from a cyclohexanedicarboxylic acid, units derived from a naphthalene dicarboxylic acid, units derived from a stilbenedicarboxylic acid, or combinations thereof. The acid component can also be made up of about 40 to 60 mole% of units that are derived from an acid and about 40 to 60 mole% of units that are derived form a second acid. For example, units derived terephthalic acids can have the acid component comprised of between 45 and 55 mole% and about 45 to 55 mole% units derived terephthalic acids. Isophthalic acid can have the acid component comprised of approximately 45 to 55 mole% units.

“Additionally, the glycol component can include units derived from cyclohexamedimethanol. Further, the glycol component can include units derived from one or more additional glycols, such as ethylene glycol, 1,2-propanediol, 1,3-propanediol, neopentyl glycol, 1,4-butanediol, 1,5-pentatnediol, 1,6-hexanediol, p-xylene glycol, 2,2,4,4-Tetramethyl-1,3-cyclobutanediol, or combinations thereof. If the polymeric material contains units that are derived multiple glycols in some cases, the glycol can contain between 75 mole% and about 98 mole% units derived primarily from a first glycol. It can also include units derived from 2 to 4 Tetramethyl-1,3-cyclobutanediol or combinations thereof.

“The filament 408 polymeric material can contain additives such as stabilizers and antioxidants, fillers or branching agents, pigments or dyes, and combinations thereof.”

The polymeric material can then be combined with the glycol to make the filament 408. The polymeric material may be fed into an extruder in pellets or as a powder. The filament 408 can be made using either a single-screw extruder or a twin-screw extruder. Sometimes, an extruder may include a melt-pump, but in others, it can not. The speed of either a single or twin screw extruder can produce filament 408 at speeds ranging from 50 to 200 rotations per hour. The speed of the single or twin screw extruders can vary from 75 to 175 rotations per hour. Another example shows that the single or twin screw extruders can rotate at speeds of 60 to 85 rotations per minutes. The extruder can also feed one or more materials to form filament 408 at a rate of 10 grams/minute up to 40 grams/minute. It can also feed from 20 grams/minute up to 30 grams per hour, or 15 grams/minute up to 25 grams/minute.

The filament 408 can be as small as 1 mm up to 5 mm in diameter and as long at least 3 cm in length. The filament 408 may have a length of up to 5 cm in some cases. The filament 408 may have a length of 30 cm in some cases. The filament 408 may have a maximum length of about 3 cm to 5 m in some instances.

“In addition, when depositing the plurality layers of filament 408 onto substrate 404, the polymeric materials can be deposited at a specific rate. To produce the plurality layers of the object, the filament 408 may be extruded onto substrate 404. The ‘rate of extrusion’ is the rate at which filament 408 can be extruded onto the substrate 404 in these cases. The rate at which filament 408 is being deposited onto substrate 404 during formation of object 412 is an example. It can range from approximately 5.5 mm3/s up to approximately 9.5 mm3/s. Another example shows that the rate at which filament 408 is placed onto substrate 404 during formation of object 412 can range from approximately 6.5 mm3/s up to 9.0 mm3/s. Another illustration shows that the rate at which filament 408 is being deposited onto substrate 404 during formation of object 412 can range from 7.6 mm3/s up to 8.7 mm3/s.

“In some cases, object 412 may have a slight loss of intrinsic viscosity relative the inherent viscosity the polymeric material used in its production.” A loss of inherent viscosity with inherent viscosity is abbreviated I.V. The equation below can be described as:

The rate at which the filament 408’s polymeric material is deposited onto substrate 404 during formation of object 412 can also affect its inherent viscosity. The filament 408 may be deposited onto the substrate at a rate of about 7 mm3/s or 8 mm3/s during the formation of object 412. In this case, the inherent viscosity of the object 412 relative the polymeric material can be as low as about 5%, about 4.5%, about 3.5%, about 3.5%, about 2.5%, about 2.5%, about 1.5%, about 1.5%, about 0.9%, about 0.3% or 0.1%. The filament 408 can be deposited onto the substrate at a rate of about 7 mm3/s or 8 mm3/s during the formation process of the object 422. In these cases, the intrinsic viscosity of the object 412, relative to the filament 408, is minimal. An example of this is the filament 408 being deposited onto substrate 404 during formation of object 412. This can result in an intrinsic viscosity loss of approximately 0.01% to 6%. Another example shows that the intrinsic viscosity of the object 412 can vary from 0.7% to 4.3% relative to the filament 408. Another example is that the filament 408 is placed onto the substrate 408 during the formation process of the object 422. This can result in an inherent viscosity of the object 412, relative to the filament 408 at a rate of about 7 mm3/s or 8 mm3/s.

“In addition, the filament 408 must be deposited onto substrate 404 at a rate of about 8 mm3/s or about 9 mm3/s during the formation of object 412. The inherent viscosity of the object 412 relative the polymeric material can not exceed about 5%, about 4.5%, about 3.5%, about 3.5% and about 2.5% respectively. The filament 408 can be deposited onto the substrate at a rate of about 8 mm3/s or about 9 mm3/s during the formation process of the object 422. In these cases, the intrinsic viscosity of the object 422, relative to the filament 408, is minimal. An example of this is that the filament 408 can be deposited onto the substrate at a rate of about 8 mm3/s or about 9 mm3/s during the formation process of object 412. The inherent viscosity of the object 412 relative the polymeric material of filament 408 ranges from about 0.1% to 4.4%. Another example is that the filament 408 can be deposited onto the substrate 408 during the formation process of the object 422. This will result in an inherent viscosity loss between the filament 408 and the polymeric material 408. It can range from 0.1% to 3.3%. Another example is that the filament 408 can be deposited onto the substrate 408 during the formation process of object 412. This will result in an inherent viscosity of the object 412 relative the polymeric material. It can range from 0.2% to 0.9%.

“Inherent viscosity can be a sign of material degradation that occurs during additive manufacturing. A material’s mechanical properties can change if it loses its inherent viscosity. Sometimes, an object made using additive manufacturing processes can become brittle because of the loss in inherent viscosity.

“The object 412 can also have a notched Izod value ranging from 35 kJ/m2 up to 60 kJ/m2. Another example is the object 412. It can have a notched Izod value ranging from 40 kJ/m2 up to 55 kJ/m2. The object 412 may also have a notched Izod value ranging from 45 kJ/m2 up to 50 kJ/m2. At the time of filing this patent application, the notched Izod value of object 412 can also be measured using the ASTM D256 standard.

“At 414 the object 412 may be removed from substrate 404. A machine such as a robot arm can be used to remove object 412 from substrate 404. A hand-held tool or a pen can also be used to remove the object 412 form the substrate 404.

“Other architectures are possible to implement the described functionality and are included in this disclosure. For the purposes of discussion, specific distributions have been made of responsibilities. However, different functions and responsibilities may be divided and distributed depending on the circumstances.

“The following examples will further describe the concepts herein with reference to these figures. These figures do not limit disclosure as described in the claims.”

“EXAMPLES”

“Example 1”

“Samples were prepared of polymeric materials with the compositions shown in Table 1. Samples 1 through 2 were made according to the techniques described in this article. Samples 3 and 4, however, were used as comparisons. The components in Table 1 were not the only ones included in Sample 4. Sample 4 also contained a trimellitic andhydride branching agent. Proton nuclear magnetic resonance (NMR) was used to determine the composition of the samples.

“TABLE 1\nCompositions for Samples 1-4\nSample 1 Sample 2 Sample 3 Sample 4\nCyclohexanedimethanol 100 mole %? 31 mole% 31 mole% 31 mole% 31 mole% 31 mole% 31 mole%nEthylene Gellycol?0 mole% 69 mole %, 69 mole %, 69 mole% 69 mole% 69 mole% 69 %nTerephthalic acid 52 mole% 100 mole%? 100 mole% 100 mole%nIsophthalic acid 48 mole%?0 Mole%??0 Mole%?0 Mole%?0 Mole%?0 Mole%?”

“Some characteristics of the samples were measured using ASTM D standards. Table 2 shows the results of sample measurements.

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