OBJECT MADE BY ADDITIVE MANUFACTURING AND METHOD TO PRODUCE SAID OBJECT

1 . A three-dimensional object created by Fused Deposition Modeling (FDM) of a modeling material from polyaryletherketones (PAEK), polyphenylsulfides, polyamide-imide, polyethersulfon, polyetherimide, polysulfon, polyphenylsulfon, polycarbonates (PC), poly(acrylonitrile butadiene styrene) (ABS), polymethylmethacrylate (PMMA), polyethyleneterephtalate (PET), polystryrene (PS), acrylonitrilstyrene acrylate, polypropylene (PP), polylactic acid (PLA), polyvinylalcohol (PVA), polyethylene (PE), polyoxymethylene, polyurethane (PU), copolymers of polyvinylalcohol and butenediolvinylalcohol and mixtures thereof, optionally filled with inorganic or organic fillers, wherein the object has a porosity of less than 5 vol %, as determined according to the porosity test procedure ‘Porosity test’ as defined in Paragraphs [0033] to [0060].

2 . The object according to claim 1 , wherein the porosity is less than 1 vol %.

3 . The object according to claim 1 , wherein the object has a leak tightness below 10×10 −6 mbar·l/s, as determined by the leak test procedure as defined in paragraphs [0061] to [0065].

4 . The object according to claim 1 , wherein an ultimate tensile strength of a test piece measured in a Z-direction is at least 70% of the ultimate tensile strength of the test piece measured in an x-direction or a y-direction, wherein the ultimate tensile strength is measured according to ISO 527-2:2012 SPECIMEN 5A.

5 . The object according to claim 1 , wherein object is prepared from a thermoplastic composition using FDM, and wherein the thermoplastic polymer is chosen from polyethylene, polypropylene, ABS, polycarbonate and polyarylether ketones (PAEK) like for example polyether ketone (PEK), polyethyer ethyer ketone (PEEK), polyether ketone ketone (PEKK), polyether ether ketone ketone (PEEKK) and polyether ether ketone ether ketone ketone (PEKEKK) and combinations thereof.

6 . The object according to claim 5 , wherein the thermoplastic polymer composition comprises at least 80 wt. % of a PAEK.

7 . The object according to claim 5 , wherein the thermoplastic polymer composition comprises at least 80 wt. % of PEEK.

8 . The object according to claim 6 , wherein a test specimen of the object having dimensions according to ISO 527-2:2012 SPECIMEN 5A made from said polymer composition by said additive manufacturing has an ultimate tensile stress according to ISO 527-2:2012 SPECIMEN 5A of at least 70 MPa.

9 . The object according to claim 1 , wherein the FDM is performed by providing a layer in an X-Y plane having X-direction and Y-direction and successively adding further layers on top of said layer in Z-direction by depositing a modeling material onto predetermined positions, wherein X-direction, Y-direction and Z-direction are perpendicular to each other, wherein the depositing step involves

a. exerting a pressure on the modeling material to feed the modeling material onto the predetermined positions;

b. determining a parameter indicative for the pressure exerted on the modeling material and

c. controlling the feeding depending on said parameter.

10 . The object according to claim 9 , wherein providing of each of the layers is performed by

a. printing contour lines of the object in the X-Y plane marking a primary area,

b. filling a first part of the primary area inside the contour lines of the object in the X, Y plane, leaving open a second part in the primary area,

c. filling the second part by the depositing step.

11 . The object according to claim 10 , wherein filling of the first part is performed by feeding the modeling material onto the predetermined positions in a flow-controlled way.

12 . An object created by Fused Deposition Modeling (FDM) from a thermoplastic composition comprising at least 80 wt. % of a polyarylether ketone (PAEK), wherein a test specimen of the object having dimensions according to ISO 527-2:2012 SPECIMEN 5A made from said polymer composition by said additive manufacturing has an ultimate tensile stress according to ISO 527-2:2012 SPECIMEN 5A of at least 70 MPa.

13 . The object according to claim 12 , wherein the FDM is performed by providing a layer in an X-Y plane having X-direction and Y-direction and successively adding further layers on top of said layer in Z-direction by depositing a modeling material onto predetermined positions, wherein X-direction, Y-direction and Z-direction are perpendicular to each other, wherein the depositing step involves

a. exerting a pressure on the modeling material to feed the modeling material onto the predetermined positions;

b. determining a parameter indicative for the pressure exerted on the modeling material and

c. controlling the feeding depending on said parameter.

and wherein providing of each of the layers is performed by

d. printing contour lines of the object in the X-Y plane marking a primary area,

e. filling a first part of the primary area inside the contour lines of the object in the X, Y plane, leaving open a second part in the primary area,

f. filling the second part by the depositing step.

14 . The object according to claim 13 , wherein the thermoplastic composition comprises at least 90 wt. % PEEK.

15 . A process for making an object according to claim 1 , wherein the process comprises the steps of:

a. exerting a pressure on the modeling material to feed the modeling material onto the predetermined positions;

b. determining a parameter indicative for the pressure exerted on the modeling material and

c. controlling the feeding depending on said parameter.

and wherein providing each of the layers is performed by

d. printing contour lines of the object in the X-Y plane marking a primary area,

e. filling a first part of the primary area inside the contour lines of the object in the X, Y plane, leaving open a second part in the primary area

f. filling the second part by the depositing step.

16 . The object according to claim 3 , wherein the porosity is less than 0.5 vol %, and wherein the object has a leak tightness below 4.3×10 −6 mbar·l/s.

17 . The object according to claim 16 , wherein the porosity is less than 0.2 vol %, wherein the object has a leak tightness between 0 and 3×10 −6 mbar·l/s.

18 . The object according to claim 17 , wherein the porosity is less than 0.01 vol %.

19 . The object according to claim 2 , wherein an ultimate tensile strength of a test piece measured in a Z-direction is at least 70% of the ultimate tensile strength of the test piece measured in an x-direction or a y-direction, wherein the ultimate tensile strength is measured according to ISO 527-2:2012 SPECIMEN 5A; and wherein wherein object is prepared from a thermoplastic composition using FDM, and wherein the thermoplastic polymer is chosen from polyethylene, polypropylene, ABS, polycarbonate and polyarylether ketones (PAEK) like for example polyether ketone (PEK), polyethyer ethyer ketone (PEEK), polyether ketone ketone (PEKK), polyether ether ketone ketone (PEEKK) and polyether ether ketone ether ketone ketone (PEKEKK) and combinations thereof.

20 . The object according to claim 19 , wherein the thermoplastic polymer composition comprises at least 90 wt. % of a PAEK, or wherein the thermoplastic polymer composition comprises at least 90 wt. % of a PEEK.