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Company OverviewStructured Polymers LLC is an Austin, Texas-based technology company that produces specialty polymer powders for sale to the additive manufacturing industry. Structured Polymers has a proprietary method to manufacture new and traditional Selective Laser Sintering (SLS) materi-als with signi!cantly improved properties at lower costs. Our team has extensive start-up, mechani-cal engineering and material development experi-ence, speci!cally in additive manufacturing area and includes Dr. Carl Deckard, the original inventor of the SLS process, the leading powder-additive manufacturing method used today.

The IndustryThe terms direct digital manufacturing, additive manufacturing, layered manufacturing, 3D-Print-ing, and rapid prototyping all refer to a collection of manufacturing methodologies, in which a part is directly manufactured from a 3D computer drawing. Introduced over 20 years ago, these methods !rst found use in engineering model and prototype development, and are now poised to revolutionize !nal-part manufacturing, replacing “old-line” manufacturing methods like compres-sion molding, injection molding and CNC machin-ing, which require expensive, time consuming tooling steps.

Direct Digital Manufacturing (DDM) has evolved into a cost e"ective way to produce complex plas-tic parts that are either expensive or impossible to be make using traditional methods. In an April 2012 article, the Economist described DDM as a disruptive technology, calling it the “factory of the future.”

Additive manufacturing technologies di"er by the material type used -- powder, !lament, or photo-polymer resin. Filament and resin-based technol-ogies are best suited for prototyping, while pow-der-based systems can be used to make full-strength production parts. For example, Boeing uses over 240 polymer powder-based DDM parts in the production of 13 di"erent airframes. Currently, SLS-type machines domi-nate the additive manufacturing market in volume of full-strength production parts.

ProblemMaterial choices and the high cost of SLS powder currently limit the wider adoption of DDM pow-der-based technology. World-wide, there are over 35,000 grades of polymer available to process using conventional manufacturing methods, yet, only a few of these choices are available for use in polymer powder additive manufacturing. Today, variations of two base polymers, Nylon12 and Nylon11 dominate this market.

Nylon12 and Nylon11 are currently precipitated from solution, which is expensive, limits the abili-ty to include additive packages, and is not adapt-able to di"erent polymer classes. Furthermore, the direct grinding of polymer pellets has not proved successful. These factors together contrib-ute to the staggering cost of Nylon12 and Nylon11. A kilogram of Nylon 12 powder currently costs $129, with approximately 60 kgs needed to fully charge many SLS machines -- the same base polymer, in raw pellet form is available for around $8-16 per kilogram when purchased in volume.

SolutionStructured Polymers addresses these market pains using a proprietary manufacturing process that co-opts the economy of scale approach of the textile industry. In our process, polymers are spun into !ber and then cut to size, e"ectively creating an equiaxed micro-pellet. Spinning and cutting are well known and commercially available tech-nologies. Structured Polymers will be able to man-ufacture SLS grade powders from any spin-able polymer, for some small !xed cost above the pellet cost. In this method of powder production, the spinning and cutting can be outsourced to one of many vendors, allowing us to easily scale up or down to meet production demands.

Spinning to !ber prior to sizing allows for the introduction of new polymers and the use of speci!c additives to enhance properties including #ame retardancy, heat de#ection temperature, UV protection, corrosion resistance, and conduc-tivity. Finally this patented manufacturing method can be extended by using multi-compo-nent !bers to make “custom-composite powders” for speci!c high volume applications. 1

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