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SummaryWe review the process rates and energy intensities of various additive processing technologies and focus on recent progress in improving these metrics for laser powder bed fusion processing of metals, and filament and pellet extrusion processing of polymers and composites. Over the last decade, observed progress in raw build rates has been quite substantial, with laser metal processes improving by about 1 order of magnitude, and polymer extrusion processes by more than 2 orders of magnitude. We develop simple heat transfer models that explain these improvements, point to other possible strategies for improvement, and highlight rate limits. We observe a pattern in laser metal technologies that mimics the development of machine tools; an efficiency plateau, where faster rates require more power with no change in energy nor rate efficiency.

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PurposeThe purpose of this paper is to present results of an investigation, where the elastic tensor based on the engineering constants of sinterized Nylon 12 is characterized and is modeled considering a transversely isotropic behavior as a function of apparent density (relative mass density).Design/methodology/approachThe ultrasound propagation velocity measurement through the material in specific directions by means of the pulse transmission method was used, relating the elastic tensor elements to the phase velocity magnitude through Christoffel's equation. In addition conventional uniaxial tensile tests were carried out to validate the used technique. Laser sintering of Nylon 12 powder (Duraform PA) has been performed at different laser energy densities, fabricating cube‐shaped coupons as well as dogbone flat coupons, using an SLS 125 former DTM machine.FindingsCorrelations for each one of the Young moduli, Shear constants and Poisson's ratios, presenting an exponential behavior as a function of the sintering degree, were generated. In addition, as the apparent density reaches a maximum value of 977 kg/m3 at an energy density of 0.032 J/mm2, the material behaves in an almost isotropic form, presenting average values for the Young modulus, Shear modulus and Poisson's ratio corresponding to 2,310 MPa, 803 MPa and 0.408, respectively.Research limitations/implicationsThe research is limited only to one type of material within the elastic range. Validation of the Young modulus measured along one direction only is performed using a tensile test machine, due to the difficulties in evaluating Poisson's ratios and Shear moduli using conventional tests.Practical implicationsThe results presented can be applied to virtual design and evaluating processes such as finite element analysis.Originality/valueThe paper incorporates detailed information regarding the complete elastic characteristics of Nylon 12, including additional measurements of the Shear moduli and Poisson's ratios not studied previously.