High-Strength Materials for 3D Printing

Gradient nesting material for 3D printing with improved interlayer adhesion. The material consists of a core layer and a cladding layer. Polymerization occurs at the interface between the layers. The core layer contains a second polymer, a polymerization aid, and catalyst. The cladding layer contains a first polymer. The polymerization aid enables chemical bonding between the polymers at the interface, improving adhesion and preventing delamination. This allows 3D printing of dissimilar materials with better mechanical properties in all directions.

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Three-dimensional printing of metal objects using composite metal materials that can be printed with a regular 3D printer and then heat treated to convert the composite into a solid metal alloy. The composite material is made by mixing a low melting point metal with a high melting point metal powder. The composite is extruded through a 3D printer nozzle and printed layer by layer based on a CAD model. After printing, the object is heat treated at temperatures above the low melting point but below the high melting point to allow the metals to alloy and form a solid metal object.

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Extrusion-based 3D printing of low-melting point metals like aluminum, magnesium, and zinc alloys creates a thixotropic fluid using proper alloy composition. Thixotropic metals have high viscosity and yield stress at low strain rates but are thin when sheared. This allows stable filament extrusion and sag resistance during printing. An extrusion system was developed with parameters optimized for printing thixotropic metals

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Powder for additive manufacturing that improves dimensional accuracy and mechanical strength of additively manufactured bodies. The powder has a surface treatment film containing a hydrophobic compound derived from a coupling agent. The film helps retain powder fluidity during printing to improve filling properties, dimensional accuracy, and strength compared to untreated powders.

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Additive manufacturing of ceramics and ceramic matrix composites that allows rapid, low-cost, and energy-efficient printing of complex ceramic parts with improved mechanical properties compared to existing ceramic printing techniques. The method involves printing a reactive powder integrated with a preceramic binder that pyrolyzes into ceramic upon heating. The powder is extruded and fixed in place using on-the-spot curing. Heat is then applied to initiate a self-sustaining ceramization reaction that rapidly converts the powder and binder into dense ceramic. The process enables freeform printing of ceramics with reduced porosity and increased mechanical performance compared to other ceramic printing methods.

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The inkjet-dischargeable curable composition for 3D printing applications that is free of titanium oxide is highly safe, inkjet-dischargeable, and has a high strength and a high whiteness after being cured. The composition contains a radical-polymerizable monomer and a hard solid component of silica particles with specific properties like particle size and refractive index. The hard solid component improves whiteness, while the other components provide inkjet-dischargeability and curing properties.

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An additively manufactured integral reinforcement member for a vehicle pillar that improves structural performance and torsional stiffness compared to conventional reinforcement methods. The reinforcement member is made by 3D printing multiple components that are then joined together to form a single unit. The additive manufacturing allows complex geometries and consolidates attachment points.

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3D printing metal objects without warping or cracking by using a tacky polymer substrate. The process involves spreading a layer of metal particles over a polymer substrate with low thermal conductivity and melting the unmasked metal with pulsed light to form each layer of the object. The polymer substrate reduces lateral heat transfer during melting, preventing warping and cracking.

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Reinforced thermoplastic powder compositions for 3D printing of objects with high mechanical properties. The compositions contain glass fibers in a specific size range along with a polyamide powder, and optionally flow agents. The glass fibers should have a length range of 50-200 µm and a maximum length below 450 µm. The reinforced 3D printed objects have superior mechanical properties like modulus, elongation, breaking stress, and heat deflection compared to injection molded counterparts.

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Blended polymer resin formulations for 3D printing composite articles with improved mechanical properties and layer adhesion compared to semicrystalline polymers like PBT. The blends use an amorphous polymer like PETG or APET blended with a semicrystalline polymer like PBT. The blended resin has higher fiber content (e.g. glass fiber) than the amorphous polymer alone. The amorphous polymer slows crystallization of the semicrystalline component during printing, improving layer bonding.

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Improving the performance of 3D printed nickel-based superalloys for aerospace and other applications, by reducing cracking that can occur during printing and heat treatment. The method involves using a two-powder mixture of high-melt superalloy powder and low-melt superalloy powder. The low-melt powder has a lower solidus temperature to reduce cracking. The high-melt powder provides high-temperature performance. The mixture ratio allows printing without hot isostatic pressing. The low-melt powder fills pores and homogenizes during heat treatment.

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A polymeric blend based support material with high Shore A hardness that enables easy removal from printed parts, without damaging them. The blend consists of two immiscible polymers, where one is the same as the modeling material. This allows 3D printing with a single extruder. The immiscible polymers separate into two phases with the harder polymer as the continuous phase. This gives the support material high hardness and strength compared to the modeling material, allowing fracture at the support-model interface when removed.

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Metal objects with solid lubricating surface layers that improve mechanical properties and reduce friction compared to conventional lubrication methods like oils. The method involves projecting microparticles onto the metal surface to induce plastic flow and create a compressive stress layer. Solid lubricating powder is then projected onto the compressive layer where it adheres tightly to form the lubricating surface layer. The compressive layer provides good adhesion and densifies the metal for improved strength.

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A method for 3D printing multi-layer structures with improved interlayer adhesion to prevent delamination. The method involves creating cavities that cross multiple layers during printing and then filling the cavities with a second material to form rivets perpendicular to the layers. The rivets compress the surrounding layers as they cool and contract, increasing adhesion.

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Three-dimensional printer systems and methods that enable stronger, faster, and more reliable 3D printing of composite parts. The systems involve using continuous core reinforced filaments that are preimpregnated and void-free. The continuous core enables improved threading and prevents clogging compared to stranded filaments. The void-free impregnation improves strength and eliminates weak spots. Other features include cutting mechanisms to avoid overruns, enlarged nozzle outlets to prevent clogs, and compression-based extrusion for convex shapes.

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Iteratively designed 3D printer that optimizes the ratio of mass to print build volume by using generative design algorithms. The printer has a frame made of sections built using additive manufacturing techniques (like directed energy deposition 3D printing) from metals like titanium or stainless steel. The frame supports a movable beam and shuttle holding the print head.

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Customized, 3D printed protective sports pads that match an individual athlete's body contours and dimensions. The pads are made by 3D printing rigid or semi-rigid filaments in a shape specific to the target body area. The filaments are then fused together by heating. An outer layer can be added for reinforcement. The pads provide better protection and fit than generic pads. The manufacturing process involves receiving body parameters, constructing a 3D model, printing the pad, and heat fusing the filaments.

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Improving the tensile strength of 3D printed green bodies to prevent damage during transportation and handling prior to fusing. The method involves selectively applying an adhesion promoter containing multihydrazide compounds like adipic dihydrazide to the binder fluid used in 3D printing. The multihydrazide adhesion promoter enhances the bonding between layers of particulate build material when forming the green body.

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Photopolymerizable resin composition for additive manufacturing of 3D printed parts with high stiffness at temperatures up to 250°C. The composition contains derivatives of diurethane dimethacrylates and other components that enable the resin to achieve high thermo-mechanical properties. The resin is used to 3D print articles that can maintain stiffness at high temperatures. It is also used in a stereolithography method for making the articles. The printed objects are subjected to post-curing to complete the polymerization and optimize properties.

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A nickel-based superalloy composition for use in selective laser melting (SLM) to enable crack-free processing of Ni-based superalloys with high gamma prime content. The alloy composition contains a minimum of 1.2 wt % Hafnium and has a Hf/C atomic ratio >1.55.

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