Fluoropolymer Ink and Process for Additive Manufacturing

Unmet Need
Due to its unique mechanical, chemical, and thermal capabilities, polytetrafluoroethylene (PTFE) is a fluoropolymer that has reached 200,000 tons in production worldwide in 2019. This number is expected to increase exponentially in the next decade because of the high demand for PTFE use from the biomedical, pharmaceutical, and aerospace industries. PTFE is incredibly versatile and offers advantageous properties such as chemical/thermal stability, hydrophobicity, and high resistance to damage. However, PTFE also has a high melt viscosity, making it challenging to fabricate complex PTFE structures when using conventional manufacturing methods. There is a high demand for a cheap, effective technique to produce complex PTFE structures for practical applications.

Technology Overview
This technology offers a novel fabrication method to 3D-print complex PTFE structures through the development of an innovative shear-thinning ink. With the utilization of a two phase manufacturing process combining Direct Ink Writing (DIW) and thermal treatment, it is now possible to customize and scale PTFE structures. In addition to keeping the beneficial mechanical properties of PTFE, it has been shown that this method of processing allows for tenability of the material properties of the object. This enables a larger design scape for PTFE structures while also employing the use of its exceptional properties, which will be critical for its future application in a variety of industries.

Stage of Development
Working prototype has been tested and described in published work

Publications
Z Jiang et al. “Direct Ink Writing of Poly(tetrafluoroethylene) (PTFE) with Tunable Mechanical Properties.”  ACS Appl Mater Interfaces. 2019 Aug 7; 11(31).

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