Printing method for thermoplastic retention device preform

Abstract

A method for forming a preform for a thermoplastic retention device is provided. The method includes providing a thermoplastic base material and blending the base material with one or more chemical agents to form a polymer blend. The chemical agents are configured to modify a polymer chain of the base material when the polymer blend is exposed to radiation. The method further includes forming the polymer blend into a filament sized for a three-dimensional printing platform and printing a preform shape from the filament using the three-dimensional printing platform. After the printed preform is hardened, the method includes exposing the printed preform shape to radiation sufficient to cause a reaction between the one or more chemical agents and the base material.

What is claimed is: 
     
         1 . A method for forming a preform for a thermoplastic retention device, the method comprising:
 providing a thermoplastic base material;   blending the base material with one or more chemical agents to form a polymer blend, the one or more chemical agents being configured to modify a polymer chain of the base material when the polymer blend is exposed to radiation;   forming the polymer blend into a filament sized for a three-dimensional printing platform;   printing a preform shape from the filament using the three-dimensional printing platform; and   exposing the printed preform shape to radiation sufficient to cause a reaction between the one or more chemical agents and the base material.   
     
     
         2 . The method of  claim 1 , wherein the thermoplastic base material includes polycaprolactone (PCL). 
     
     
         3 . The method of  claim 2 , wherein the one or more chemical agents include one or more trifunctional monomers. 
     
     
         4 . The method of  claim 2 , wherein the one or more chemical agents include exactly two trifunctional monomers. 
     
     
         5 . The method of  claim 4 , wherein the one or more chemical agents include triallylcyanurate and trimethylolpropane trimethacrylate. 
     
     
         6 . The method of  claim 2 , wherein the one or more chemical agents include two active crosslinking agents in equal amounts by weight. 
     
     
         7 . The method of  claim 1 , wherein the three-dimensional printing platform includes a fused deposition modeling (FDM)-based three-dimensional printer. 
     
     
         8 . The method of  claim 1 , wherein printing the preform shape includes:
 printing the preform shape with a consistent thickness, wherein the preform shape includes a flat base layer area and a reinforcement area, the reinforcement area having an increased pattern density compared to the base layer area.   
     
     
         9 . The method of  claim 1 , wherein printing the preform shape includes:
 printing a base layer having a first thickness, and   printing a reinforcement layer, having a second thickness, on top of a portion of the base layer that is less than the entirety of the base layer, wherein the reinforcement layer comprises the same material as the base layer.   
     
     
         10 . The method of  claim 1 , wherein printing the preform shape includes:
 printing a three-dimensional, contoured profile that is configured for placement over a particular body feature.   
     
     
         11 . The method of  claim 1 , wherein exposing the printed preform shape to radiation includes:
 exposing the printed preform shape to between 0.1 to 1.0 Megarads of gamma radiation.   
     
     
         12 . The method of  claim 1 , further comprising:
 after the exposing, securing the printed preform shape to a rigid frame.   
     
     
         13 . The method of  claim 1 , wherein printing the preform shape includes:
 printing one or more solid portions and one or more lattice portions within a single layer.   
     
     
         14 . The method of  claim 1 , further comprising
 providing a second thermoplastic base material;   blending the second thermoplastic base material with one or more of the chemical agents to form a second polymer blend; and   forming the second polymer blend into a second filament sized for the three-dimensional printing platform,   wherein printing the preform shape comprises printing the preform shape to include material from the filament and the second filament using the three-dimensional printing platform.   
     
     
         15 . The method of  claim 14 , wherein the second polymer blend, after the exposing the printed preform shape to radiation, exhibits different material properties than the polymer blend. 
     
     
         16 . The method of  claim 1 , wherein, when exposing the printed preform shape to radiation, the reaction lengthens the polymer chain of the base material. 
     
     
         17 . The method of  claim 1 , wherein the polymer blend includes polycaprolactone (PCL), triallylcyanurate, and trimethylolpropane trimethacrylate.