Three-Dimensional Printing Using Carbon Nanostructures

Abstract

Objects produced by conventional three-dimensional printing methods often have limited structural quality. Printing compositions to address this issue can include a solidifiable matrix and a plurality of carbon nanostructures dispersed in the solidifiable matrix. The carbon nanostructures include a plurality of carbon nanotubes that are branched, crosslinked, and share common walls with one another. Three-dimensional printing methods utilizing such printing compositions can include: depositing the printing composition in a layer-by-layer deposition process, and while depositing the printing composition, applying a focused input of microwave radiation in proximity to a location where the printing composition is being deposited. The focused input of microwave radiation heats the carbon nanostructures at the location and promotes consolidation of the printing composition within an object being produced by the layer-by-layer deposition process.

1 - 22 . (canceled) 
     
     
         23 . A method for layer-by-layer, three-dimensional printing, comprising
 using a printing composition containing a solidifiable matrix and a plurality of carbon nanostructures dispersed in the solidifiable matrix, the carbon nanostructures including a plurality of carbon nanotubes that are branched, crosslinked, and/or share common walls with one another.   
     
     
         24 . The method of  claim 23 , wherein the carbon nanostructures are in the form of a flake material free of a growth substrate. 
     
     
         25 . The method of  claim 23 , wherein the solidifiable matrix comprises a thermoplastic polymer. 
     
     
         26 . The method of  claim 25 , wherein the thermoplastic polymer is selected from the group consisting of polyketones, acrylonitrile-butadiene- styrene (ABS), polyetheretherketones (PEEK), polyamides, polyolefins, polyethyleneimine (PEI), polycarbonates, and combinations thereof 
     
     
         27 . The method of  claim 23 , wherein the solidifiable matrix comprises a curable material. 
     
     
         28 . The method of  claim 23 , wherein a loading of carbon nanostructures in the solidifiable matrix ranges between 0.1% and 30% by weight. 
     
     
         29 . The method of  claim 23 , wherein using a printing composition comprises depositing the printing composition as a plurality of droplets. 
     
     
         30 . The method of  claim 23 , wherein the carbon nanostructures are functionalized for covalent attachment to the solidifiable matrix.