Process for forming a consumable filament

Abstract

The present disclosure provides a filament for use in an extrusion-based additive manufacturing system made from or containing a propylene ethylene copolymer having: ethylene derived units content ranging from about 3.0 wt % to about 12.0 wt %, based upon the weight of the propylene ethylene copolymer; MFR L (Melt Flow Rate according to ISO 1133, condition L, at 230° C. and 2.16 kg load) from about 4 to about 20 g/10 min; and xylene solubles measured at 25° C. from about 3 wt % to about 30 wt %, based upon the weight of the propylene ethylene copolymer. The disclosure further provides an extrusion-based additive manufacturing system made from or containing the filament as well as 3D printed articles prepared from the system.

What is claimed is: 
     
       1. A process for forming a consumable filament comprising:
 forming a filament, wherein the filament comprises: 
 a propylene ethylene copolymer having:
 an ethylene derived units content ranging from 3.0 wt % to 12.0 wt %, based upon the weight of the propylene ethylene copolymer; 
 a MFR L (Melt Flow Rate according to ISO 1133, condition L, at 230° C. and 2.16 kg load) from 4 to 20 g/10 min; and 
 a xylene solubles content, measured at 25° C., from 3 wt % to 30 wt %, based upon the weight of the propylene ethylene copolymer, and 
 
 wherein the filament is formed within an extrusion-based additive manufacturing system. 
 
     
     
       2. The process according to  claim 1 , wherein the propylene copolymer has an ethylene derived units content from 3.5 wt % to 10.0 wt %, based upon the weight of the propylene ethylene copolymer. 
     
     
       3. The process according to  claim 1 , wherein the propylene copolymer has a MFR L from 5 to 10 g/10 min. 
     
     
       4. The process according to  claim 1 , wherein the propylene copolymer has a xylene solubles content, measured at 25° C., from 4 wt % to 25 wt %, based upon the weight of the propylene ethylene copolymer. 
     
     
       5. The process according to  claim 1 , wherein the propylene copolymer has an ethylene derived units content from 3.8 wt % to 8.0 wt %, based upon the weight of the propylene ethylene copolymer. 
     
     
       6. The process according to  claim 1 , wherein the propylene copolymer has a MFR L ranging from 6 to 8 g/10 min. 
     
     
       7. The process according to  claim 1 , wherein the filament has a constant diameter having a variation of +/−0.05 mm. 
     
     
       8. The process according to  claim 1 , wherein the filament has a constant diameter having a variation of +/−0.03 mm. 
     
     
       9. The process according to  claim 1 , wherein the filament has a diameter selected from the group consisting of: (a) 1.75 mm+/−0.05 mm; and (b) 3 mm+/−0.05 mm. 
     
     
       10. The process according to  claim 1 , wherein the filament has a diameter selected from the group consisting of (a) 1.75 mm+/−0.03 mm; and (b) 3 mm+/−0.03 mm. 
     
     
       11. The process of  claim 1  comprising the step of forming a 3D printed article with the filament.