US Patent 11859103 Polymer particles and related additive manufacturing methods

Polymer particles that comprise a thermoplastic polymer and a nucleating agent may be useful in additive manufacturing methods where warping may be mitigated. For example, a method of producing said polymer particles may comprise: mixing a mixture comprising a thermoplastic polymer, a nucleating agent, a carrier fluid, and optionally an emulsion stabilizer at a temperature at or greater than a melting point or softening temperature of the thermoplastic polymer to emulsify a thermoplastic polymer melt in the carrier fluid; cooling the mixture to form polymer particles; and separating the polymer particles from the carrier fluid, wherein the polymer particles comprise the thermoplastic polymer, the nucleating agent, the emulsion stabilizer, if included, and wherein the polymer particles have a crystallization temperature that is substantially the same as a crystallization temperature of the thermoplastic polymer prior to mixing.