Parametric Analysis of the Selective Laser Sintering Process

Qualitative and quantitative analyses are required to develop Selective Laser Sintering into a viable Manufacturing process. A simplified mathematical model for sintering incorporating the heat tJ;ansfer equation. and the sintering rate equation, but using temperature independent thermal properties, is presented in this paper. A practical result is the calculation of sintering depthdeftned as the depth of powder where the void fraction is less than 0.1 as a function of control parameters, such as the laser power intensity, the laser scanning velocity, and the initial bedtemperature. We derive the general behavior of laser sintering. A comparison of model predictions with laser sinterlng tests is provided.Mechanical Engineerin

Cryogenic Mechanical Alloying of Poly (ether ether ketone) - Polycarbonate Composite Powders for Selective Laser Sintering

Mechanical alloying is a solid state processing technique traditionally used in the metallurgical industry to extend solubility limits in alloy systems. Mechanical alloying can also be used to blend polymer systems at ambient or cryogenic temperatures. In this work, cryogenic mechanical alloying was employed to create composite powders of Poly (ether ether ketone) (PEEK) - Polycarbonate (PC) for use in selective laser sintering applications. The microstructural development of the PEEK-PC system that occurs during laser sintering and the effects of this microstructure on mechanical properties of the laser sintered parts was investigated.Mechanical Engineerin

Additive manufacturing for solid oxide cell electrode fabrication

© The Electrochemical Society.Additive manufacturing can potentially offer a highly-defined electrode microstructure, as well as fast and reproducible electrode fabrication. Selective laser sintering is an additive manufacturing technique in which three-dimensional structures are created by bonding subsequent layers of powder using a laser. Although selective laser sintering can be applied to a wide range of materials, including metals and ceramics, the scientific and technical aspects of the manufacturing parameters and their impact on microstructural evolution during the process are not well understood. In the present study, a novel approach for electrode fabrication using selective laser sintering was evaluated by conducting a proof of concept study. A Ni-patterned fuel electrode was laser sintered on an yttria-stabilized zirconia substrate. The optimization process of laser parameters (laser sintering rate and laser power) and the electrochemical results of a full cell with a laser sintered electrode are presented. The challenges and prospects of using selective laser sintering for solid oxide cell fabrication are discussed

Laser Sintering of Stainless Steel using Resin Powder

We tried laser sintering of 316L stainless steel powder using resin powder. The laser sintering conditions such as laser power, scan speed and scan pitch with a YAG laser, and the influence of additional resin powder on the density and the tensile properties of the sintered alloy were investigated experimentally. The tensile specimen was laser-sintered with a YAG laser, and then debound and sintered in a vacuum furnace. The tensile specimen was successfully fabricated. The relative density and the tensile strength varied with the additional resin powder, and the optimum weight percentage of additional resin powder was around 4%.The relative density of the sintered alloy was approximately 85%, and the tensile strength and elongation of the sintered alloy were more than 280 MPa and 15% respectively.Mechanical Engineerin

Selective laser sintering of hydroxyapatite reinforced polyethylene composites for bioactive implants and tissue scaffold development

Selective laser sintering (SLS) has been investigated for the production of bioactive implants and tissue scaffolds using composites of high-density polyethylene (HDPE) reinforced with hydroxyapatite (HA) with the aim of achieving the rapid manufacturing of customized implants. Single-layer and multilayer block specimens made of HA-HDPE composites with 30 and 40 vol % HA were sintered successfully using a CO2 laser sintering system. Laser power and scanning speed had a significant effect on the sintering behaviour. The degree of particle fusion and porosity were influenced by the laser processing parameters, hence control can be attained by varying these parameters. Moreover, the SLS processing allowed exposure of HA particles on the surface of the composites and thereby should provide bioactive products. Pores existed in the SLS-fabricated composite parts and at certain processing parameters a significant fraction of the pores were within the optimal sizes for tissue regeneration. The results indicate that the SLS technique has the potential not only to fabricate HA-HDPE composite products but also to produce appropriate features for their application as bioactive implants and tissue scaffolds

Laser Micro Sintering – A Quality Leap through Improvement of Powder Packing

Laser micro sintering, a modification of selective laser sintering for freeform fabrication of micro-parts, was continuously upgraded since its first application. Poor density of the powder layers has been a persisting problem that had to be dealt with from the beginning. One solution was the application of high intensity q-switched laser pulses. Compaction of the material and improvement of the sinter resolution was achieved. But with these pulse-regimes only limited density of the sintered body has been achievable. Recently special efforts have been made to get rid of or at least reduce these drawbacks by markedly higher compaction of the respective powder layers. There is clear evidence that with sufficiently compacted powder layers even laser micro sintering with continuous radiation should be feasible. Till recently laser sintering of metal had been applied mainly to produce monolithic components. With the upgraded technique direct generation of micro devices with freely movable subassemblies can be possible.Mechanical Engineerin

Investigation of the Oven Process in Indirect Metal Laser Sintering

This paper deals with the optimization of Indirect Metal Laser Sintering. Different experimental analyses have proven that the oven process is highly responsible for the part distortion. By means of polished micrograph sections and thermogravimetric and dilatometric investigations, the oven process has been divided into four main steps: polymer removal, solid-state sintering, infiltration and liquid-phase sintering. Further experiments were carried out at higher temperature phases of the oven process, using modified process parameters. The aim of this research is to improve the knowledge about the oven process. In another step, this process will be simulated by means of finite element analysis in order to minimize the part distortion.Mechanical Engineerin

Development of Nanocomposite Powders for the SLS Process to Enhance Mechanical Properties

In an effort to fabricate prototypes with improved mechanical properties in the dual laser sintering process, functionalized graphite nanoplatelets were added to the PA-12 powder to produce a nanocomposite powder. The PA-12 powder was chosen as the matrix polymer because it has features conducive to laser sintering such as relatively low melting temperature and high mechanical properties. The GNPs were oxidized through a nitric acid treatment to improve the interfacial bonding. The resulting nanocomposite powder was layered and sintered by laser without any sign of agglomeration. Although the result is preliminary, it nevertheless shows the suitability of the nanocomposite powder for the laser sintering process.Mechanical Engineerin

Recent advances in 3D printing of biomaterials.

3D Printing promises to produce complex biomedical devices according to computer design using patient-specific anatomical data. Since its initial use as pre-surgical visualization models and tooling molds, 3D Printing has slowly evolved to create one-of-a-kind devices, implants, scaffolds for tissue engineering, diagnostic platforms, and drug delivery systems. Fueled by the recent explosion in public interest and access to affordable printers, there is renewed interest to combine stem cells with custom 3D scaffolds for personalized regenerative medicine. Before 3D Printing can be used routinely for the regeneration of complex tissues (e.g. bone, cartilage, muscles, vessels, nerves in the craniomaxillofacial complex), and complex organs with intricate 3D microarchitecture (e.g. liver, lymphoid organs), several technological limitations must be addressed. In this review, the major materials and technology advances within the last five years for each of the common 3D Printing technologies (Three Dimensional Printing, Fused Deposition Modeling, Selective Laser Sintering, Stereolithography, and 3D Plotting/Direct-Write/Bioprinting) are described. Examples are highlighted to illustrate progress of each technology in tissue engineering, and key limitations are identified to motivate future research and advance this fascinating field of advanced manufacturing