The present disclosure relates to method of making three-dimensional (3D) objects using an additive manufacturing system wherein the part material comprises a polymeric component comprising at least one poly(ether ether ketone) polymer (PEEK) having a weight average molecular weight (Mw) ranging from 75,000 to 100,000 g/mol (as determined by GPC), for example in the form of filaments or spherical particles, for use in additive manufacturing systems to print 3D objects.

A block comprised of a copolymer is obtained by ring-opening polymerization of a cyclic polyarylene sulfide, so that a block copolymer is produced to have a maximum peak molecular weight measured by size exclusion chromatography (SEC) in a range of not less than 2,000 and less than 2,000,000 and have a unimodal molecular weight distribution in this range.

A process for manufacturing a three-dimensional object from a powder by selective sintering the powder using electromagnetic radiation. The powder includes recycled PAEK. In one embodiment, the powder includes recycled PEKK. In one embodiment, the powder includes first recycle PEKK and second recycle PEKK. In one embodiment, the powder consists essentially of recycled PEKK. The process may include the step of maintaining a bed of a selective laser sintering machine at approximately 300 degrees Celsius and applying a layer of the powder to the bed. The average in-plane tensile strength of the three-dimensional object is greater than that of a three-dimension object manufactured by selective sintering using a powder including an unused PEKK powder.

A polymer composition that contains a polyaryletherketone and a plurality of reinforcing fibers is provided. The reinforcing fibers have an aspect ratio of from about 1.5 to about 10, which is defined as the cross-sectional width of the fibers divided by the cross-sectional thickness of the fibers.

Aspects of the present disclosure generally describe polyarylether ketones and methods of use. In some aspects, a composition includes one or more polymers of formulae (I), (II), or (III):

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The present disclosure provides a process for producing a polymer, said process comprising polymerising a monomer system comprising a compound of formula: Ar—O—Ar—C(═O)—X—C(═O)—Ar—O—Ar in a reaction medium comprising a Lewis acid where: X is an aliphatic moiety and Ar is an aromatic moiety.

The present invention provides a gel comprising a physical network formed of polymer chain crystallites interconnected by amorphous chain segments. Functionalization of the chain segments between the crystallites forms a blocky distribution of functionality along the chain whereby the functionalities are concentrated in groups consisting of one or more functionalities, separated by non-functionalized runs of crystallizable segments of the polymer. Removal of the solvent from the gels, without reducing the gel volume, forms an aerogel.

Methods of preparing phthalonitrile coating compositions are provided, including phthalonitrile sprays, phthalonitrile pastes, and phthalonitrile composite films. In embodiments, such a method comprises, heating a phthalonitrile precursor composition comprising a bisphthalonitrile compound to a temperature and for a period of time to form a phthalonitrile prepolymer composition comprising a bisphthalonitrile prepolymer; cooling the phthalonitrile prepolymer composition to ambient temperature and pulverizing the phthalonitrile prepolymer composition to form particles; combining the particles with a liquid medium to form a phthalonitrile solution; optionally, adding an additive to the phthalonitrile solution; and mixing the phthalonitrile solution to form a phthalonitrile coating composition.

There is disclosed a composition, suitable for use in dynamic applications at low temperature, the composition comprising a first polymeric material (A) having a repeat unit of formula

—O-Ph-O-Ph-CO-Ph-  I

wherein Ph represents a phenylene moiety; and
a second polymeric material (B) having a repeat unit of formula

(F2C—CF2)—  II

and further comprising a pigment;
wherein said composition has a melt viscosity of at least 0.50 kNsm-2. There is also disclosed an assembly or apparatus, a use and a polymeric micropellet.

The present disclosure relates to an additive manufacturing (AM) method for making a three-dimensional (3D) object, comprising a) depositing successive layers of a powdered material (M), at least partially recycled, comprising at least one poly(ether ketone ketone) (PEKK), having a phosphorus content of more than 30 ppm, as measured by Inductively Coupled Plasma Optical Emission Spectrometry (ICP-OES), and b) selectively sintering each layer prior to deposition of the subsequent layer.