Amorphous polyaryletherketone and blends thereof for use in additive manufacturing

Abstract

A material for use with a 3D printer comprises a polyaryletherketone (PAEK) having an amorphous morphology. In some embodiments, the material also includes one or more further compounds having an amorphous morphology. In some further embodiments, the material includes, in addition to an amorphous PAEK, a compound having a semi-crystalline morphology.

1 - 53 . (canceled) 
     
     
         54 . A composition for use with a three-dimensional (3D) printer, comprising a first compound and a second compound different than the first compound, wherein the first compound is a polyaryletherketone (PAEK), and wherein the composition is amorphous. 
     
     
         55 . The composition of  claim 54 , wherein the second compound comprises an additional PAEK. 
     
     
         56 . The composition of  claim 55 , wherein the PAEK is more amorphous than the additional PAEK. 
     
     
         57 . The composition of  claim 54 , wherein the second compound does not include a PAEK. 
     
     
         58 . The composition of  claim 54 , wherein the PAEK is polyetherketone, polyetherketoneketone, polyetheretherketoneketone, or polyetherketoneetherketoneketone. 
     
     
         59 . The composition of  claim 58 , wherein the PAEK is polyetherketone. 
     
     
         60 . The composition of  claim 58 , wherein the PAEK is polyetheretherketone. 
     
     
         61 . The composition of  claim 58 , wherein the PAEK is polyetheretherketoneketone. 
     
     
         62 . The composition of  claim 54 , further comprising a filler material having a melting temperature that is greater than a glass transition temperature of the PAEK. 
     
     
         63 . The composition of  claim 62 , wherein the filler material comprises one or more members selected from the group consisting of chopped carbon fibers, chopped glass fibers, chopped aramid fibers, continuous carbon fiber, continuous glass fiber, continuous polyethylene fiber, milled carbon, milled glass, graphite, graphene, carbon nanotubes, and graphene nanoplatelets. 
     
     
         64 . The composition of  claim 63 , wherein the filler material comprises carbon nanotubes. 
     
     
         65 . The composition of  claim 63 , wherein the filler material comprises continuous carbon fiber. 
     
     
         66 . The composition of  claim 62 , wherein the filler material is encapsulated within the PAEK. 
     
     
         67 . The composition of  claim 54 , wherein a weight ratio of the first compound to the second compound is at least 1:1. 
     
     
         68 . The composition of  claim 67 , wherein the weight ratio is from about 1:1 to 19:1. 
     
     
         69 . The composition of  claim 54 , wherein the composition is included in a filament. 
     
     
         70 . The composition of  claim 69 , wherein a diameter of the filament is from about 6 millimeters (mm) to 13 mm. 
     
     
         71 . The composition of  claim 69 , wherein a diameter of the filament is from about 1 mm to 2 mm. 
     
     
         72 . The composition of  claim 54 , wherein the composition is included in a pellet. 
     
     
         73 . The composition of  claim 54 , wherein the composition is included in a material roll.