Materials for powder-based additive manufacturing processes

1. A consumable micro-pellet for use in a powder-based additive manufacturing system, the consumable micro-pellet characterized by a core portion extending along a longitudinal length of the consumable micro-pellet, the core portion compositionally comprising a first thermoplastic material and a shell portion extending along the longitudinal length of the consumable micro-pellet and at least partially encasing the core portion, the shell portion compositionally comprising a second thermoplastic material that is different from the first thermoplastic material, characterized by the consumable micro-pellet having an average cross-sectional diameter ranging from 10 microns to 250 microns, an average ratio between the length of the micro-pellet and the diameter of the micro-pellet that ranging from 1:2 to 3:1, and further characterized by the consumable micro-pellet being configured to be melted and used to form a plurality of solidified layers of a three-dimensional object, the layers at least partially retaining cross-sectional profiles corresponding to the core portion and the shell portion of the consumable micro-pellets.

2. The consumable micro-pellet of claim 1 , further characterized by the first thermoplastic material being a first semi-crystalline polymeric material selected from a group of semi-crystalline polymers consisting of polyamides, polyethylenes, including low-density polyethylene, medium-density polyethylene and high density polyethylene, polypropylenes, including isotactic polypropylenes, syndiotactic polypropylenes, branched and linear variations thereof, polyetheretherketones, olyoxymethylene acetals, polytetrafluoroethylenes, polypheneylene sulfides, polybutylene terephthalates, copolymers thereof, and combinations thereof and the second thermoplastic material characterized by being a second semi-crystalline polymeric material selected from the same group of semi-crystalline polymers.

3. The consumable micro-pellet of claim 1 , further characterized by the first thermoplastic material being a first polyamide material selected from a group of polyamide polymers consisting of aliphatic nylon polyamides, such as nylon 6, nylon 6-6, nylon 6-10, nylon 6-12, nylon 10, nylon 10-10, nylon 11, nylon 12, copolymers thereof and combinations thereof, and the second thermoplastic material characterized by being a second polyamide material polymeric material selected from the same group of polyamide polymers.

4. The consumable micro-pellet of claim 1 , further characterized by at least one of the thermoplastic materials having one or more additives, modifiers or common plastic reinforcement materials incorporated to modify the mechanical, electrical magnetic, thermodynamic, processing, aesthetic or biocompatibility properties of the base polymers.

5. The consumable micro-pellet of claim 1 , further characterized by one or more of thermoplastic materials being an amorphous thermoplastic material.

6. The consumable micro-pellet of claim 1 , further characterized by the core portion and the shell portion arrangement in the micro-pellet being an alternative bi-component portion arrangement.

7. The consumable micro-pellet of claim 1 , further characterized by the micro-pellet being three or more portions.

8. The consumable micro-pellet of claim 1 , further characterized by the first thermoplastic material being a first semi-crystalline polymeric material having a first peak crystallization temperature, and wherein the second thermoplastic material is a second semi-crystalline polymeric material having a second peak crystallization temperature that is greater than the first peak crystallization temperature.

9. A three-dimensional object built with a powder-based additive manufacturing system, the three dimensional object comprising, a plurality of solidified layers each produced with a powder-based additive manufacturing system from a plurality of consumable micro-pellets each characterized by having a first portion and a second portion, wherein the first portion compositionally comprises a first thermoplastic material, and wherein the second portion comprises a second thermoplastic material that is different from the first thermoplastic material; and further characterized by at least a portion of the plurality of solidified layers at least partially retaining cross-sectional profiles corresponding to the first portion and the second portion of the consumable micro-pellet.

10. The three-dimensional object of claim 9 , further characterized by the consumable micro-pellets having bimodal or higher order size distribution.

11. A method of manufacturing a consumable multi-component micro-pellet characterized by the steps of first spinning a multi-component fiber with an average cross-sectional diameter ranging from 10 microns to 250 microns, said fiber characterized by having a first portion extending along a longitudinal length of the fiber, the first portion compositionally comprising a first thermoplastic material; and by having a second portion extending along the longitudinal length of the fiber, the second portion compositionally comprising a second thermoplastic material that is different from the first thermoplastic material and then cutting the fiber to an average length between 0.5 times the diameter of the fiber to 3 times the diameter of the fiber.

12. The method of manufacturing a consumable micro-pellet of claim 11 , further characterized by the spinning step being followed by a drawing step prior to cutting.

13. The method of manufacturing a consumable micro-pellet of claim 11 , further characterized by the cutting step being with the fiber being in the form of tow of at least 1,000,000 dTex.

14. The method of manufacturing a consumable micro-pellet of claim 11 , further characterized by the addition of a rounding step following the cutting step.