Compositions and methods for fused filament fabrication

Abstract

A composition for fused filament fabrication may include polylactic acid resin and talc. The composition may range from 50% by weight to 99% by weight polylactic acid resin, and from 7% by weight to 40% by weight talc. The composition may be configured as filaments or pellets adapted to be used in a fused filament fabrication process. A method for generating a resin-based structure may include providing a resin source that may include polylactic acid resin and talc. The resin source may include from 50% by weight to 99% by weight polylactic acid resin, and from 7% by weight to 40% by weight talc. The method may also include heating the resin source to a temperature greater than the melting temperature for semi-crystalline resins or significantly greater than glass transition temperature for amorphous resins, and depositing the heated resin source in a layered manner to form the resin-based structure.

1 . A composition for fused filament fabrication, the composition comprising:
 polylactic acid resin and talc,   wherein the composition ranges from 50% by weight to 99% by weight polylactic acid resin,   wherein the composition ranges from 7% by weight to 40% by weight talc, and   wherein the composition is configured as a shape adapted to be used in a fused filament fabrication process.   
     
     
         2 . The composition of  claim 1 , wherein the talc has a median particle size less than 12 microns. 
     
     
         3 - 7 . (canceled) 
     
     
         8 . The composition of  claim 1 , wherein the talc has a top particle size less than 150 microns. 
     
     
         9 - 12 . (canceled) 
     
     
         13 . The composition of  claim 1 , wherein the talc has a Hegman rating of 2 or greater. 
     
     
         14 - 16 . (canceled) 
     
     
         17 . The composition of  claim 1 , wherein the talc has a BET surface area greater than 2 m 2 /g. 
     
     
         18 - 29 . (canceled) 
     
     
         30 . The composition of  claim 1 , wherein the talc has an oil absorption less than 60 grams per 100 grams of talc. 
     
     
         31 - 34 . (canceled) 
     
     
         35 . The composition of  claim 1 , wherein the talc has a shape factor greater than 10. 
     
     
         36 - 48 . (canceled) 
     
     
         49 . The composition of  claim 1 , wherein the composition ranges from 10% by weight to 30% by weight talc. 
     
     
         50 - 52 . (canceled) 
     
     
         53 . The composition of  claim 1 , further comprising at least one additional mineral. 
     
     
         54 . (canceled) 
     
     
         55 . The composition of  claim 1 , wherein the composition further comprises at least one of plasticizers, impact modifiers, pigments, dyes, colorants, stabilizers, and other polymer additives or processing aids, configured to modify resin properties. 
     
     
         56 . (canceled) 
     
     
         57 . A method for generating a resin-based structure, the method comprising:
 providing a resin source comprising polylactic acid resin and talc, wherein the resin source comprises from 50% by weight to 99% by weight polylactic acid resin, and wherein the resin source comprises from 7% by weight to 40% by weight talc;   heating the resin source to a temperature at least equal to the glass transition temperature of the resin source; and   depositing the heated resin source in a layered manner to form the resin-based structure.   
     
     
         58 . An article having improved heat resistance, comprising:
 a semi-crystalline polymer material having a heat deflection temperature equal to or greater than about 70 C,   wherein the article comprises fused filaments of the semi-crystalline polymer material.   
     
     
         59 . The article of  claim 58 , wherein the semi-crystalline polymer material comprises a functional mineral. 
     
     
         60 . The article of  claim 59 , wherein the functional mineral comprises talc. 
     
     
         61 . The article of  claim 59 , wherein the functional mineral is present in an amount ranging from 7% by weight to 40% by weight. 
     
     
         63 . The article of  claim 59 , wherein the functional mineral has a shape factor greater than 10. 
     
     
         64 . The article of  claim 59 , wherein the functional mineral has an oil absorption less than 60 grams per 100 grams of mineral. 
     
     
         65 . The article of  claim 59 , wherein the functional mineral has a median particle size less than 12 microns. 
     
     
         66 . The article of  claim 58 , wherein the semi-crystalline polymer material comprises polylactic acid resin. 
     
     
         67 . The article of  claim 58 , wherein the semi-crystalline polymer material has a crystalline content of at least about 30%.