Selective laser sintering (SLS) is a leading process for developing rapid prototype objects by selectively fusing layers of powder according to numerically defined cross‐sectional geometry. The process has the potential to become an indispensable industrial tool. However, continuous process improvement is necessary. Improved understanding of the parameter effects on the process response is expected to lead to process advances. In this work the analytical problem describing the energy delivery, heat transfer and sintering process along with other pertinent phenomena is studied. Physical experiments and implementation of a numerical simulation are conducted using Bisphenol‐A polycarbonate. The effects of selected parameters on the SLS process response are examined. The primary parameters of interest are the laser power, laser beam velocity, hatch spacing, laser beam spot size and scan line length. This work shows that the secondary process parameters, delay period and number of effective exposures have a significant influence on the process response.

Develops an understanding of the energy delivery system and determines how the scanning speed and part strength are affected by particular scanning parameters. Describes a high speed process workstation incorporating a variable beam spot size. Presents a more accurate sintering model which can be used to speed up the scanning process.The authors wish to thank the Office of Naval Research for its financial assistance through contract No. N001-94-1-0489 and DTM Corporation for the donation of equipment.

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