Provided are amorphous and at least partially crystalline polyetherimide compositions having a comparatively narrow particle size distribution and are particularly suited for additive manufacturing processes. The compositions comprise a population of polyetherimide particulates are characterized as having a zero-shear viscosity sufficiently low so as to achieve a coalescence of at least 0.5, and preferably of about 1.0, as characterized by the Frenkel model at a temperature less than 450 C.

A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.

The invention pertains to a method for manufacturing a three-dimensional object with an additive manufacturing system, such as an extrusion-based additive manufacturing system, a selective laser sintering system, and/or an electrophotography-based additive manufacturing system, comprising providing a support material comprising more than 50% wt. of a semi-crystalline polyamide [polyamide (A)] having a melting point, as determined according to ASTM D3418, of at least 250 C. and possessing a water absorption at saturation, by immersion in water at 23 C., of at least 2% wt.

A system for thermoforming an object is provided. The system includes a mold and a pressure-box. The mold has a surface that defines a shape of the object and includes two or more portions of differing porosities. The pressure-box is operative to generate a pressure differential across the surface. The two or more portions apply the pressure differential at different loads, based at least in part on the differing porosities, to a material disposed onto the surface so as to form the object by deforming the material into the shape.

An article and a method of forming an article are provided. The article includes a thermoplastic build material and a polymeric support material. The polymeric support material is selectively removable from the thermoplastic build material through immersion in a solvent. The method of forming an article includes forming a part through additive manufacturing with a thermoplastic build material and a polymeric support material, immersing the part in a solvent, selectively softening the polymeric support material with the solvent, removing the part from the solvent, and separating the polymeric support material from the thermoplastic build material. Another method of forming an article includes forming a part through additive manufacturing with a thermoplastic build material and a polymeric support material, immersing the part in a solvent, selectively dissolving the polymeric support material with the solvent, and removing the thermoplastic build material from the solvent.

An apparatus performing as a base for printing 3D objects using high temperature thermoplastics employing additive manufacturing methods is provided. The apparatus comprises a heated build platform, a thin removable plate secured on top of the build platform, a high temperature polymer coating applied over the removable plate, and surface treatment of high temperature polymer coating to maintain adhesion between 3D object and printing surface. Also, the removable plate has low coefficient of thermal expansion compared to build platform below it, for avoiding bowing of the plate as it is heated due to heated build platform, hence providing flat printing surface. The thin removable plate allows 3D objects to pop off the plate upon cooling, without damaging the polymer coating, the plate, or the object. It also allows for continuous operation of printing, while the plate is released for cooling, a new plate is installed for printing.

A tool for forming a composite structure may include two or more segments formed from a polymer material. The tool may further include a crush insert disposed between the two or more segments. The tool may also include a support shaft coupled between the two or more segments. A method of forming a mandrel may include forming segments of the mandrel through an additive manufacturing process. The method may further include assembling the segments relative to one another. The method may also include positioning a crush insert between each of the segments. A method of fabricating a composite structure is also disclosed.

A method of curing a part in a mold using induction heated tooling is provided. In preferred embodiments, the method comprises placing a material that may be cured with pressure and heat in tooling made from a non-metallic material wherein the tooling includes a mold cavity that forms the part. Creating an electro-magnetic field across the tooling using induction coils. Applying pressure to the tooling and heating a metallic material contained in channels formed in the tooling around the mold cavity of the part.

A tool for laying up composite material to form a workpiece having a target contour is disclosed. The tool includes a support structure including an elongated member having a longitudinal axis, and support plates connected to the elongated member and spaced apart from each other along the longitudinal axis. The elongated member includes a metallic material. The tool also includes a non-metallic backing structure connected to the support plates, the non-metallic backing structure comprising a working surface that includes a backing contour complementary to the target contour.

An apparatus performing as a base for printing 3D objects using high temperature thermoplastics employing additive manufacturing methods is provided. The apparatus comprises a heated build platform, a thin removable plate secured on top of the build platform, a high temperature polymer coating applied over the removable plate, and surface treatment of high temperature polymer coating to maintain adhesion between 3D object and printing surface. Also, the removable plate has low coefficient of thermal expansion compared to build platform below it, for avoiding bowing of the plate as it is heated due to heated build platform, hence providing flat printing surface. The thin removable plate allows 3D objects to pop off the plate upon cooling, without damaging the polymer coating, the plate, or the object. It also allows for continuous operation of printing, while the plate is released for cooling, a new plate is installed for printing.