Additive manufacturing using polyurea materials
Methods of additive manufacture using coreactive components are disclosed. Thermosetting compositions for additive manufacturing are also disclosed.
1. A reactive additive manufacturing composition, comprising:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the first viscosity is within ±20% of the second viscosity; wherein the viscosity is measured using an Anton Paar MCR 301 or 302 rheometer with a 25 mm-diameter parallel plate spindle, an oscillation frequency of 1 Hz and amplitude of 0.3%, and with a rheometer plate temperature of 25° C.
2. The composition of claim 1 , wherein,
the polyisocyanate comprises a polyisocyanate monomer, a polyisocyanate prepolymer, or a combination thereof; and
the polyamine comprises a polyamine monomer, a polyamine prepolymer, or a combination thereof.
3. The composition of claim 2 , wherein,
each of the polyisocyanate monomer and the polyamine monomer independently has a molecular weight less than 600 Daltons; and
each of the polyisocyanate prepolymer and the polyamine prepolymer independently has a molecular weight from 1,000 Daltons to 20,000 Daltons.
4. The composition of claim 1 , wherein the reactive additive manufacturing composition comprises a polymeric rheology modifier.
5. The composition of claim 4 , wherein the polymeric rheology modifier comprises a reactive polymeric rheology modifier.
6. The composition of claim 4 , wherein the polymeric rheology modifier is selected from a polyethylene, a polyethylene/ethylene copolymer, a polypropylene/ethylene copolymer, and a combination of any of the foregoing.
7. The composition of claim 4 , wherein each of the first component and the second component independently comprises from 1 wt % to 20 wt % of the polymeric rheology modifier, wherein wt % is based on the total weight of the first component or the second component.
8. The composition of claim 1 , wherein the reactive additive manufacturing composition comprises from 0.1 wt % to 40 wt % of a filler, wherein wt % is based on the total weight of the reactive additive manufacturing composition.
9. The composition of claim 8 , wherein the filler comprises an inorganic filler, an organic filler, a low-density filler, an electrically conductive filler, magnetic filler, or a combination of any of the foregoing.
10. An object formed using the reactive additive manufacturing composition of claim 1 .
11. The object of claim 10 , wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.
12. A method of reactive additive manufacturing using a reactive additive manufacturing composition, wherein,
the reactive additive manufacturing composition comprises:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes; and
the method comprises:
providing the first component into a first pump;
providing the second component into a second pump, wherein the second prepolymer is reactive with the first prepolymer;
pumping the first component from the first pump, and the second component from the second pump through a mixer to provide a reactive additive manufacturing composition; and
depositing the reactive additive manufacturing composition through a nozzle connected to the mixer.
13. The method of claim 12 , wherein each of the first pump and the second pump independently comprises a syringe pump, a peristaltic pump, or a progressive cavity pump.
14. The method of claim 12 , wherein the mixer comprises a static mixer, a dynamic mixer, or a combination thereof.
15. The method of claim 12 , wherein depositing comprises extruding the reactive additive manufacturing composition.
16. The method of claim 12 , wherein pumping comprises extruding each of the first component and the second component into the mixer.
17. The method of claim 12 , wherein,
the method comprises extruding the reactive additive manufacturing composition to form an extrudate; and
a cross-sectional profile of the extrudate is characterized by a variable ratio of the first component to the second component.
18. The method of claim 17 , wherein the ratio refers to the mol % ratio of the coreactive components in the extrudate.
19. The method of claim 17 , wherein the ratio refers to the equivalents ratio of the functional groups in the extrudate.
20. The method of claim 17 , wherein the ratio refers to the wt % ratio of the coreactive components in the extrudate.
21. The method of claim 17 , wherein a surface of the extrudate has an excess of one or more functional groups.
22. The method of claim 12 , wherein depositing comprises depositing the reactive additive manufacturing composition from a single nozzle.
23. The method of claim 12 , wherein depositing comprises spraying the reactive additive manufacturing composition.
24. An object fabricated using the method of claim 12 .
25. A reactive additive manufacturing composition, comprising:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the reactive additive manufacturing composition comprises a polymeric rheology modifier.
26. The composition of claim 25 , wherein the polymeric rheology modifier is selected from a polyethylene, a polyethylene/ethylene copolymer, a polypropylene/ethylene copolymer, and a combination of any of the foregoing.
27. The composition of claim 25 , wherein each of the first component and the second component independently comprises from 1 wt % to 20 wt % of the polymeric rheology modifier, wherein wt % is based on the total weight of the first component or the second component.
28. The composition of claim 25 , wherein the reactive additive manufacturing composition comprises from 0.1 wt % to 40 wt % of a filler, wherein wt % is based on the total weight of the reactive additive manufacturing composition.
29. The composition of claim 28 , wherein the filler comprises an inorganic filler, an organic filler, a low-density filler, an electrically conductive filler, magnetic filler, or a combination of any of the foregoing.
30. An object formed using the reactive additive manufacturing composition of claim 25 .
31. The object of claim 30 , wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.
32. An object formed from a reactive additive manufacturing composition, wherein the reactive additive manufacturing composition comprises:
a first component comprising a polyisocyanate and having a first viscosity; and
a second component comprising a polyamine and having a second viscosity,
wherein the reactive additive manufacturing composition is characterized by a tack free time of greater than 3 minutes, and
wherein the object comprises a plurality of layers, wherein adjacent layers forming the object are covalently bonded.
33. The object of claim 32 , wherein the first viscosity is within ±20% of the second viscosity; wherein the viscosity is measured using an Anton Paar MCR 301 or 302 rheometer with a 25 mm-diameter parallel plate spindle, an oscillation frequency of 1 Hz and amplitude of 0.3%, and with a rheometer plate temperature of 25° C.
34. The object of claim 33 , wherein the reactive additive manufacturing composition comprises a polymeric rheology modifier.