Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions comprising a plurality of piezoelectric particles and a polymer material comprising at least one thermoplastic polymer and at least one thermally curable polymer precursor. At a sufficient temperature, the at least one thermally curable polymer precursor may undergo a reaction, optionally also undergoing a reaction with the piezoelectric particles, and form an at least partially cured printed part. The piezoelectric particles may be mixed with the polymer material and remain substantially non-agglomerated when combined with the polymer material. The compositions may define a form factor such as a composite filament, a composite pellet, or an extrudable composite paste, which may be utilized in forming printed part by extrusion, layer-by-layer deposition, and thermal curing.

The present invention relates to an enhanced method for the manufacture of a plastic component (135), in particular a cushioning element for sports apparel, the method comprising: opening a mold (100) by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts (110, 112) and wherein the amount by which the mold is opened influences an available loading volume of the mold, loading a material comprising expanded particles (130) into the loading volume, closing the mold into a closed position, wherein during closing of the mold the mold parts are moved together over different distances (140) in different areas of the mold, compressing the expanded particles by closing the mold and fusing at least the surfaces of the expanded particles to mold the plastic component.

The present invention relates to an enhanced method for the manufacture of a plastic component (135), in particular a cushioning element for sports apparel, the method comprising: opening a mold (100) by a predetermined amount into a loading position, wherein the mold comprises at least two mold parts (110, 112) and wherein the amount by which the mold is opened influences an available loading volume of the mold, loading a material comprising expanded particles (130) into the loading volume, closing the mold into a closed position, wherein during closing of the mold the mold parts are moved together over different distances (140) in different areas of the mold, compressing the expanded particles by closing the mold and fusing at least the surfaces of the expanded particles to mold the plastic component.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions comprising a plurality of piezoelectric particles located in a polymer matrix comprising a first polymer material and a sacrificial material that are immiscible with each other. The sacrificial material, which may comprise a second polymer material, may be removable from the first polymer material under specified conditions. The piezoelectric particles may remain substantially non-agglomerated when combined with the polymer matrix. The polymer matrix may be treated to remove the sacrificial material to introduce a plurality of pores. The compositions may have a form factor such as a composite filament, a composite pellet, a composite powder, or a composite paste. Additive manufacturing processes may comprise forming a printed part by depositing the compositions layer-by-layer.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions comprising a plurality of piezoelectric particles dispersed in at least a portion of a polymer matrix comprising first polymer material and a sacrificial material, the sacrificial material being removable from the polymer matrix to define a plurality of pores in the polymer matrix. The piezoelectric particles may remain substantially non-agglomerated when combined with the polymer matrix. The sacrificial material may comprise a second polymer material. The compositions may define a composite having a form factor such as a composite filament, a composite pellet, a composite powder, or a composite paste. Additive manufacturing processes may comprise forming a printed part by depositing the compositions layer-by-layer and introducing porosity therein.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component. Printed parts having piezoelectric properties may be formed using a composite filament comprising a plurality of piezoelectric particles dispersed in a thermoplastic polymer. The composite filaments may be formed through melt blending and extrusion. The composite filament is compatible with fused filament fabrication and has a length and diameter compatible with fused filament fabrication, and the piezoelectric particles are substantially non-agglomerated and dispersed along the length of the composite filament. The piezoelectric particles may remain substantially non-agglomerated when dispersed in the thermoplastic polymer through melt blending. Additive manufacturing processes may comprise heating such a composite filament at or above a melting point or softening temperature thereof to form a softened composite material, and depositing the softened composite material layer by layer to form a printed part.

Methods, systems, and devices are disclosed for implementing a stretchable nanoparticle-polymer composite foams that exhibit piezoelectric properties. In one aspect, a nanoparticle-polymer composite structure includes a curable liquid polymer; piezoelectric nanoparticles; and graphitic carbons.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions comprising a plurality of piezoelectric particles and a polymer material comprising at least one thermoplastic polymer and at least one photocurable polymer precursor. The at least one photocurable polymer precursor may undergo a reaction in the presence of electromagnetic radiation, optionally undergoing a reaction with the piezoelectric particles, in the course of forming the printed part. The piezoelectric particles may be mixed with the polymer material and remain substantially non-agglomerated when combined with the polymer material. The compositions may define a form factor such as a composite filament, a composite pellet, or an extrudable composite paste, which may be utilized in forming printed parts by extrusion and layer-by-layer deposition, followed by curing.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions comprising a polymer matrix comprising a first polymer material and a second polymer material that are immiscible with each other, and a plurality of piezoelectric particles substantially localized in one of the first polymer material or the second polymer material. The piezoelectric particles may remain substantially non-agglomerated when combined with the polymer matrix. The compositions may define a form factor such as a composite filament, a composite pellet, or an extrudable composite paste. Additive manufacturing processes using the compositions may comprise forming a printed part by depositing the compositions layer-by-layer.

Parts made by additive manufacturing are often structural in nature, rather than having functional properties conveyed by a polymer or other component present therein. Printed parts having piezoelectric properties may be formed using compositions that are extrudable and comprise a plurality of piezoelectric particles and a plurality of carbon nanomaterials dispersed in at least a portion of a polymer material. The piezoelectric particles may remain substantially non-agglomerated when combined with the polymer material. The polymer material may comprise at least one thermoplastic polymer, optionally further containing at least one polymer precursor. The compositions may define an extrudable material that is a composite having a form factor such as a composite filament, a composite pellet, a composite powder, or a composite paste. Additive manufacturing processes using the compositions may comprise forming a printed part by depositing the compositions layer-by-layer.