A consumable material configured for use in an additive manufacturing system includes a polymeric matrix having polyetherersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable for processing in the additive manufacturing system and having a Tg that is about 190° C. or greater and a coefficient of thermal expansion of less than about 30 μm/(m.Math.° C.). The consumable material is suitable for use in 3D printing of composite mold tools.

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.

The present disclosure relates to an additive manufacturing (AM) method for making a three-dimensional (3D) object, comprising a) the provision of providing a powdered polymer material (M) comprising at least one polymer (P1) having a melting temperature (Tm) greater than 270 C., as measured by differential scanning calorimetry (DSC) according to ASTM D3418, and at least one polymer (P2) having a glass transition temperature (Tg) between 130 C. and 240 C., and no melting peak, as measured by differential scanning calorimetry (DSC) according to ASTM D3418, b) the deposition of successive layers of the powdered polymer material; and c) the selective sintering of each layer prior to the deposition of the subsequent layer, wherein the powdered polymer material (M) is heated before step c) to a temperature Tp ( C.): Tp<Tg+25, wherein Tg ( C.) is the glass transition temperature of the P2 polymer.

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.

The present invention relates to a process for foaming thermoplastic elastomers comprising a blowing agent, where the elastomer is heated by means of electromagnetic radiation to such an extent that the elastomer at least partly melts and foams to give a foam, wherein the frequency of the electromagnetic radiation is in the range from 0.01 GHz to 300 GHz. Further subject matter encompasses materials suitable for this process and the use thereof.

A consumable material configured for use in an additive manufacturing system includes a polymeric matrix having polyetherersulfone (PES) in a range of between about 30 wt % and about 85 wt % of the polymeric matrix and polyphenylene sulfide (PPS) in a range between about 15 wt % and about 70 wt % of the polymeric matrix, wherein the polymeric matrix is in a media form suitable for processing in the additive manufacturing system and having a Tg that is about 190 C. or greater and a coefficient of thermal expansion of less than about 30 m/(m.Math. C.). The consumable material is suitable for use in 3D printing of composite mold tools.