Elastic Materials for 3D Printing

Method for optimizing 3D printed part properties by dynamically generating the print path and material extrusion amounts based on user-defined center-of-gravity and weight information. The method involves acquiring designation data for the 3D object's center-of-gravity and weight, generating print models with extrusion paths and amounts based on that data, and then controlling the printer to follow those models. This allows customizing the print to balance factors like stability, warpage, and support requirements based on the object's properties.

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A method for 3D printing items using semi-crystalline polymers like polyethylene that prevents warping and adhesion failures during printing. The method involves selectively cooling and heating the build plate and printed layers to optimize crystallization and melting. This allows the semi-crystalline polymers to adhere to the plate during printing and then solidify for strength. The steps include: 1) depositing the polymer on the plate at a high temperature to melt it and adhere it. 2) cooling the deposited layers below their crystallization temperature. 3) raising the plate temperature to below the polymer's melting point. 4) continuing printing with the higher plate temperature and lower layer temperature to prevent warping and adhesion failures. 5) removing the printed item at room temperature. This sequence enables the semi-crystall

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Method for defining the material properties of plastic parts during 3D printing to enable on-demand customization of properties like stiffness, strength, and toughness. The method involves actively varying extrusion parameters like temperature, flow rate, and nozzle diameter during printing to manipulate the microstructure of the extruded material. This allows selective modification of properties in specific regions of the printed part. The technique involves using a 3D printer with features like variable nozzle diameter, temperature control, and speed variators to enable real-time adjustment of extrusion parameters. By varying parameters like temperature and flow rate at different locations, the method allows inducing specific microstructures and hence tailored properties in those regions.

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High-precision 3D printing of viscoelastic paste materials like ceramic slurries using a customized printing system. The system uses a movable build plate instead of a fixed one to enable precise layer-by-layer printing of viscoelastic pastes. An extruder deposits paste onto the plate, followed by a scraper to level it. This improves accuracy compared to full-layering methods. The plate moves up/down for each layer. A conveyor belt cleans the scraper. The system has components like clamps, motors, belts, rails, etc. to enable the customized printing process.

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Reducing warpage and making it easier to separate 3D printed objects from the build plate. The method involves using a different material for the initial layer compared to subsequent layers. This initial layer integrates with the build plate to reduce warping. Then using a different material for the subsequent layers allows easier separation as the initial layer holds the object to the build plate. This avoids needing a release agent or excessive force to remove the object.

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3D printing silicone elastomer articles with complex shapes using water-based supports that can be easily removed and recycled. The method involves 3D printing a silicone elastomer with a cross-linkable composition and support with a composition containing nano clay and water. The clay-water support is compatible with the silicone printing material and allows for printing complex shapes. The support can be dissolved and reused after printing.

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Foam particles are used in additive manufacturing (3D printing) to make articles like athletic equipment. The method involves arranging foam particles of thermoplastic elastomers and using energy beams like lasers to selectively heat and fuse the foam particles together. This allows the article to be constructed layer by layer.

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Body-mounted components like orthoses have improved flexibility and resistance to breakage when bent. The components are made by 3D printing using a resin material with high elongation at break when stretched. This elongation property allows the 3D-printed parts to bend and stretch without breaking.

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3D printed structures made from liquid crystal elastomers that can change shape in response to environmental stimuli. The structures are printed using stereolithography and have segments in different orientations to enable 3D-to-3D shape change. To achieve this, liquid crystal alignment is controlled during printing using magnetic fields.

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3D printing of elastomeric rubber seals using a 3D printer with two print heads. The first head extrudes the rubber material, which is heated and mixed in an extruder like a screw to cure it partially. The extruder is also heated. The second head prints a support structure of a more rigid material around the rubber layers to prevent sagging. The rubber layers are printed on a heated bed.

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Method to produce low warpage and high precision 3D printed parts using polyaryletherketone (PAEK) materials like PEEK and PEKK. The method involves blending PEEK and PEKK resins with different melting points to create a composite filament. This composite filament is used to print the 3D part. The blended resins have different crystallization rates that helps regulate the crystallization during printing to reduce warping. The part is then machined using small feed rates and high speeds to further reduce internal stresses. Finally, annealing is done to eliminate residual stresses and further reduce warpage.

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Customizable vehicle cushion components made using 3D printing with lattice structures of interconnected 3D cells. The lattice cells in the cushion can have different geometries and elastic moduli to achieve varying levels of support and comfort. For example, face-centered cubic lattice cells can provide higher modulus support, while body-centered cubic cells can provide lower modulus cushioning. The lattice sections can be integrated into a single monolithic structure.

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Customizable 3D printed trim articles, like headrest buns, are made from a lattice matrix with tunable elastic modulus. The lattice is 3D printed with additive manufacturing techniques. The lattice is printed in sections, and the curing time of each section is adjusted to vary its stiffness. Longer curing times increase the elastic modulus of the lattice. The overall lattice can be customized for different stiffness regions by printing sections with different curing times and moduli.

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Self-adaptive matrix extrusion method for 3D printing that reduces microscopic pores and improves mechanical strength of printed parts without changing the printing path. The method determines the optimal matrix extrusion amount at each print point based on the geometric spacing between points. By adjusting the matrix extrusion for overfilled and underfilled areas, it allows self-adaptive extrusion matching the print path. This reduces porosity and enhances part strength.

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High yield stress ceramic stereolithography 3D printing material with self-supporting force that allows complex ceramic parts to be printed without the need for contact supports. The material composition includes acrylate compounds, plasticizers, initiators, ceramic powders, dispersants, and polyamide waxes. The unique formulation enables ceramic powders with high volume fractions of 55-70% while still providing self-support for 3D printing without collapsing or sagging. This enables non-contact support strategies for complex structures without needing to remove supports after printing which can damage the parts.

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3D printing overhangs without supports using a technique where the successive layers of thermoset material have offset beads compared to the underlying layer. This prevents sagging and provides stability. The offset beads are achieved by depositing the layers with a delay between them. The delay allows the material to partially cure before the next layer is printed. This forms a mechanical interlock between the layers that prevents sagging when printing overhangs. The offset beads are also smaller than the underlying beads for higher resolution.

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Additively manufacturing shaped bodies like anatomic models with regions having different mechanical properties by site-selectively depositing thermoplastic and non-thermoplastic materials layer by layer. The method involves using a 3D printer with two print heads, one for thermoplastic material and one for non-thermoplastic material. The heads are moved independently to selectively deposit the materials in different regions to create shapes with varying mechanical properties. The non-thermoplastic material could be biocompatible materials like hydrogels or silicone rubbers to mimic soft tissues.

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3D printing low viscosity materials that cannot be printed by conventional methods without overspray between layers. The technique involves printing layers using two passes. The first pass creates a mold or support structure for the low viscosity material to be printed in the second pass. This allows printing of low viscosity materials without overspray by enclosing them in a mold. The mold material provides initial support until the low viscosity material gains enough strength to self-support. The mold is then removed.

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High-precision 3D printing equipment and method for viscoelastic paste materials that allows accurate 3D printing of viscoelastic materials like ceramic slurries. The equipment has a movable printing table, extrusion head, conveyor belt, scraper, and unloading block. The table moves up/down while the extrusion head and scraper move left/right. This allows precise layer thickness control. The scraper removes excess material after extrusion. The unloading block cleans scraper accumulation. The conveyor moves material. This enables accurate multi-layer printing of viscoelastic materials.

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A material extrusion 3D printing method for creating complex 3D models using high-solid-content inorganic and metal pastes. The method involves suspending the paste in a support material with at least 40% solid content. The paste is extruded from a 3D printer into the support material, which provides structure and prevents collapse. The support is then cured to fix the shape. The high-solid-content paste allows better mechanical properties compared to low-solid-content pastes. The support material prevents deformation during extrusion and allows curing without reducing paste solid content. This enables printing complex structures with higher solid content pastes.

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A method for unsupported 3D printing of three-dimensional negative Poisson's ratio structures using conventional 3D printing techniques without the need for support material. The method involves designing the structure in a way that allows it to be printed layer by layer without any overhanging features that would require supports during printing. The structure is made up of repeating tetrahedral frameworks with hexadecagonal units of varying thicknesses. This allows the structure to have negative Poisson's ratio properties when assembled. The key is to arrange the units so that each layer has larger outlines than the previous one, allowing the structure to be built without support.

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Printing foldable ceramic objects by first 3D printing elastic objects using a polymer ink containing ceramic precursor particles. The 3D printed elastic objects are then folded into complex shapes to form pre-strained elastic objects. Finally, the pre-strained elastic objects are converted into ceramic objects by pyrolysis. This results in foldable ceramic objects with shapes that are preserved during the ceramization process due to the pre-straining step.

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A method for producing shaped articles using three-dimensional printing with improved mechanical properties. The method involves using a resin composition with short fibers (1-300 um) and high aspect ratio (3-200) in 3D printing applications. This allows easier shaping with lower print speeds compared to long fibers. It also reduces layer delamination and warping issues. The short fibers align during printing, improving mechanical properties of the printed parts. The short fiber composition can be used to 3D print functional parts with enhanced strength and stiffness compared to unfilled resins.

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3D printed structures with controlled flexibility and counterforce for applications like shoes, seats, and padding. The structures have walls made of alternating layers of flexible and rigid materials. The rigid layers provide structural integrity, while the flexible layers allow deformation. The rigid layer rigidity exceeds the flexible layer rigidity. This configuration allows the structure to compress without collapsing fully, absorbing force, and returning to shape. The flexible layers deform first, preventing the collapse of the rigid layers.

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A method for 4D printing ceramic objects with shape-shifting capabilities. The method involves extruding ceramic precursor inks to form elastic ceramic structures, subjecting them to tensile stress, then joining and releasing the stress to allow the structures to morph into a 4D printed elastomeric object. This object is then converted into the final 4D printed ceramic object through pyrolysis or oxidation. The elastic precursor inks allow shaping and morphing during printing, while the conversion process transforms them into rigid ceramic.

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3D printing method for creating isotropic, high-strength 3D printed objects by using a printable composition with two thermoplastic polymers where one polymer has higher viscosity than the other under printing conditions. The higher viscosity polymer provides interlayer adhesion while the lower viscosity polymer enables easy extrusion. This combination results in objects with improved mechanical properties compared to using a single polymer with high viscosity. The higher viscosity polymer acts as a binder between layers while the lower viscosity polymer allows extrusion.

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A 3D printed structure with expanded dimensions when heated. The structure is made by 3D printing a mixture of a thermoplastic material and a thermal expansion material. The thermoplastic material is 50-90% of the total weight, and the thermal expansion material is 10-50% of the total weight. When the printed object is heated, the thermal expansion material expands more than the thermoplastic material, causing the overall structure to expand proportionally. This allows rapid production of complex shapes with the 3D printer, as the expansion occurs during post-processing heating rather than during printing.

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Method for 3D printing that reduces warping and shrinkage of printed objects. The method involves using a composite material containing glass fibers and a thermoplastic resin. The composite is melted and extruded to form the 3D model. The glass fibers suppress thermal deformation compared to using just the thermoplastic resin. The glass fiber length can be 0.1-2mm and fiber content 1-40% by mass. This composite material can be used as pellets for 3D printing.

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3D printing method for preparing shape-free self-deformable shape memory smart materials without requiring manual shaping. The method involves pre-stretching the extruded filaments during 3D printing by adjusting the distance between the extruder head and bottom plate. This imparts prestress that can be fixed into temporary shapes. The printed samples can then spontaneously deform when heated above the glass transition temperature due to the stored prestress. By varying printing height and angles, multi-mode self-deformation is achieved. The 3D printed shape-free self-deformable shape memory smart materials have applications in areas like space systems, underwater robots, and self-assembly systems where remote self-deformation is desired.

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3D printing method that reduces warping of printed objects by using a sandwich structure with layers of materials with different glass transition temperatures. The method involves 3D printing a part with alternating layers of a lower transition temperature material between layers of a higher transition temperature material. This prevents warping because the lower transition temperature material allows the part to expand and contract more than the higher transition temperature material during cooling, minimizing differential shrinkage and distortion. The part is printed on a heated surface above its glass transition temperature to further reduce warping. The lower transition temperature material can be a plasticizer or modified polymer to adjust its properties.

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A method called drawn fused filament fabrication (DFFF) for 3D printing objects with improved interior structures and finer features compared to conventional FFF. In DFFF, a larger diameter extruder nozzle is used to deposit a thicker initial layer of material. Then, a thinning process is applied where a second nozzle with a smaller diameter extracts a portion of the initial layer to form thinner, drawn filaments. This allows creating internal structures and features with smaller diameters than the original nozzle size. The extracted material can be recycled. The drawn filaments are also less affected by gravity and can connect between sidewalls without sagging.

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3D printing method using core-shell filaments to produce items with reduced stress and improved reliability compared to conventional 3D printing. The method involves 3D printing layers with a shell made of a first thermoplastic material and a core made of a second thermoplastic material. The first material has low glass transition temperature and high elasticity, while the second material has high stiffness. This core-shell structure allows local tuning of physical properties for stress reduction and reliability improvements compared to homogeneous layers. The core-shell filaments can be printed using existing fused deposition modeling (FDM) printers with modified nozzles.

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Printing curved ceramic objects like cellphone back plates using a method that involves 3D printing deformable elastomer objects, deforming them into complex shapes, and then transforming the deformed elastomer into ceramic. The key steps are: 1) 3D printing elastomer objects using ink with particles and polymers, 2) deforming the printed elastomer into desired shapes, 3) transforming the deformed elastomer into ceramic. This allows creating curved ceramic objects that are difficult to mold or cast. The elastomer deformation is limited by a high-temperature object with a predefined curvature to shape the ceramic. The ceramic transformation occurs via pyrolysis in a vacuum or inert atmosphere.

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A method for 3D printing objects using a fused deposition modeling (FDM) printer that allows embedding solid fibers in the printed part. The method involves feeding both the 3D printable material and solid fibers through the printer nozzle during printing. A separate fiber supply unit feeds the fibers. The fiber supply unit rotates the fibers around their axis as the printer head turns to compensate for torque. This prevents fiber protrusion from the printed part. The fiber diameters are controlled relative to layer height and width to avoid distortion. The method provides a way to embed fibers like carbon or glass in 3D printed parts using FDM printers.

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3D printing materials optimized for printing large, strong objects suitable for construction applications. The materials contain additives like fine powders, fibers, or aggregates mixed with the base material used in 3D printing. These additives fill gaps and bridge layers to improve packing density and layer bonding. They address the weaknesses of conventional 3D printed objects with poor interface strength between layers. The additives are chosen carefully to achieve desired mechanical properties. This allows using existing 3D printers like binder jetting or extrusion to print construction-grade objects that can support weight and have structural integrity.

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3D printing method that enables customizing the material properties like hardness and color at specific locations of a 3D model to create objects with diverse performance and multi-color capabilities. The method involves determining the optimal material for a particular print position based on the required properties. This allows configuring the material composition to match specific needs at each location. By tailoring the materials at each point, it enables printing objects with customized material characteristics.

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3D printing method to produce objects with reinforced interior structures. The method involves printing an outer structure using a first material, and then filling the enclosed interior space with a filler material that has a liquid or paste component above the melting point of the outer material. This filler material is introduced into the enclosed space after the outer structure is printed. The filler material solidifies or polymerizes inside the outer structure, creating a reinforced interior. The filler material can be reinforced with fibers to further enhance mechanical properties. The filler material temperature allows it to flow and fill the enclosed space, while the outer structure provides a boundary.

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3D printing method to improve mechanical properties of 3D printed objects by embedding reinforcement structures inside the printed part during the printing process. Channels containing a low-rigidity material are formed within the 3D print as it's being printed. This allows the low-stiffness material to act as a reinforcement and crack stopper, preventing localized fiber failure and improving out-of-plane strength. The channels are filled with a curable material that cures after printing to create the embedded reinforcement structure.

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A manufacturing method and apparatus for creating 3D thin shell structures with smooth surfaces and the ability to use materials like soft elastomers or hollow structures that can't be easily formed using conventional laminated manufacturing. The method involves scanning the object to be formed, fixing a cutting material, cutting it into a workpiece based on the scanned data, then extruding a thin shell material on the workpiece surface to create the desired 3D structure. The cutting and extrusion steps are integrated into a single module to avoid errors from using separate machines for each process.

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A flexible filament for 3D printing that can be smoothly fed through the extrusion mechanism of a Fused Deposition Modeling (FDM) 3D printer. The filament has a core made of a thermoplastic elastomer for flexibility, with reinforcement lines extending along the length on the outer surface. These reinforcement lines are made of a different thermoplastic material. The reinforced outer layer provides rigidity for feeding while the elastomer core allows flexibility. This allows the filament to be smoothly fed through the extrusion mechanism of an FDM printer, unlike highly flexible filaments made entirely of elastomer. The reinforced filament can also be used to print flexible 3D objects with soft touch. The reinforcement lines are dissolved after printing to leave a flexible part with the core material.

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A 3D printing method and printer that enables creating stronger and smoother 3D printed objects. The method involves filling a 3D object with fiber-reinforced plastic in the inner layers, followed by filling the outer layers with a liquid thermosetting resin. The resin is then cured to solidify. This allows the fiber-reinforced plastic to provide strength and voids for resin penetration, while the outer resin layer provides a smooth finish. The printer has separate printheads for the fiber-reinforced plastic and resin.

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3D printing apparatus that can produce objects with soft physical properties by varying the viscosity of the printing material according to pressure. The apparatus uses a Bingham Plastic Model printing material that has reduced viscosity when subjected to high pressure. This allows easy dispensing of the material. When the pressure is released, the material recovers its original viscosity, resulting in a product with soft properties. The apparatus has a storage unit, dispensing unit, and pressure control to adjust viscosity, as well as an optional temperature control to maintain semi-solid coexistence.

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3D printing objects with user-defined material properties like elasticity by using microstructures to approximate the desired behavior. The method involves generating a library of microstructures that can be combined during 3D printing to provide elements of an object with desired material parameters. The microstructures are designed to have specific elasticity values. By printing varying configurations of these microstructures within an object, it allows extending the range of reproducible materials using single-material 3D printers. It approximates multi-material objects without needing multi-material printers.

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