Experimental metrics of the powder layer quality in the selective laser sintering process

Lupo, Marco; Ajabshir, Sina Zinatlou; Sofia, Daniele; Poletto, Massimo

doi:10.1016/j.powtec.2023.118346

Cited by 21 publications

(9 citation statements)

References 36 publications

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“…The PES powder was sourced from a company in Shanghai. PES, a thermoplastic polymer, exhibits several key features as a powder material, including an irregular block particle shape, a particle diameter ranging from 0 to 58 µm, and a density ranging from 0.7 to 1.32 g/cm 3 . After the sieving process, the PCP underwent drying at 100 °C using electrical heating for a duration of 4 h. Subsequently, the dried PCP was manually combined with PES powder, and a high-speed mixer was used to achieve a high level of uniformity and obtain homogeneous powder mixtures with maximum dispersion and consistent color.…”

Section: Raw Materialsmentioning

confidence: 99%

“…In 1988, Deckard, affiliated with the prestigious University of Texas at Austin, introduced selective laser sintering (SLS), an innovative additive manufacturing (AM) process [1,2]. SLS is a computer-aided manufacturing (CAM) technique utilized in AM to construct 3D components based on a computer-aided design (CAD) model [3]. Thus, through the use of SLS technology, parts with complex designs and shapes can be manufactured, resulting in high-accuracy components [4][5][6].…”

Section: Introductionmentioning

confidence: 99%

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Effects of Particle Size on Mechanical Properties and Forming Accuracy of Prosopis chilensis Powder/Polyethersulfone Composites Produced via Selective Laser Sintering

Abdelmagid,

Idriss,

Yang

2024

Polymers

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Wood–plastic composites are becoming increasingly recognized for their sustainability and their potential for use in various production processes. Nevertheless, enhancing their mechanical strength continues to be a difficult challenge. The objective of this research was to improve the mechanical strength of wood–plastic composite components manufactured through selective laser sintering (SLS). This was achieved by integrating a sustainable composite material, Prosopis chilensis (PCP), with polyethersulfone (PES) to form a composite referred to as PCPC. This study showcased the effect of various PCP particle sizes on mechanical strengths, dimensional accuracies (DAs), and surface roughness of PCPC parts manufactured using AFS-360 SLS. Single-layer sintering was employed to assess PCPC powder’s formability with varying PCP particle sizes, and various tests were conducted to understand the materials’ thermal properties and analyze particle dispersion and microstructure. The results demonstrated that PCP particle sizes ≤ 0.125 mm significantly enhanced the mechanical strength, forming quality, and DA compared to other particle sizes and pure PES. Key findings for PCPC parts with PCP ≤ 0.125 mm included a bending strength of 10.78 MPa, a tensile strength of 4.94 MPa, an impact strength of 0.91 kJ/m2, and a density of 1.003 g/cm3. Post-processing further improved these parameters, confirming that optimizing PCP particle size is crucial for enhancing the mechanical properties and overall quality of PCPC parts produced via SLS.

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Section: Raw Materialsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Effects of Particle Size on Mechanical Properties and Forming Accuracy of Prosopis chilensis Powder/Polyethersulfone Composites Produced via Selective Laser Sintering

Abdelmagid,

Idriss,

Yang

2024

Polymers

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“…This is performed using laser energy, which melts and fuses particles while simultaneously maintaining the operating temperature within the steady sintered range provided by the light source. As a result of the complexity of management and the difficulty in reaching high temperatures, which results in delayed diffusions, residual tension in printed goods is formed in the printed product manufacturing process [107]. It is required to treat the material after it has been heated since stress is dependent on both the variation in temperature and properties, including its melting point, diffusion kinetics, and surface tension.…”

Section: Powder Bed Fusionmentioning

confidence: 99%

Promising New Horizons in Medicine: Medical Advancements with Nanocomposite Manufacturing via 3D Printing

Li,

Khan,

Chen

et al. 2023

Polymers

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Three-dimensional printing technology has fundamentally revolutionized the product development processes in several industries. Three-dimensional printing enables the creation of tailored prostheses and other medical equipment, anatomical models for surgical planning and training, and even innovative means of directly giving drugs to patients. Polymers and their composites have found broad usage in the healthcare business due to their many beneficial properties. As a result, the application of 3D printing technology in the medical area has transformed the design and manufacturing of medical devices and prosthetics. Polymers and their composites have become attractive materials in this industry because of their unique mechanical, thermal, electrical, and optical qualities. This review article presents a comprehensive analysis of the current state-of-the-art applications of polymer and its composites in the medical field using 3D printing technology. It covers the latest research developments in the design and manufacturing of patient-specific medical devices, prostheses, and anatomical models for surgical planning and training. The article also discusses the use of 3D printing technology for drug delivery systems (DDS) and tissue engineering. Various 3D printing techniques, such as stereolithography, fused deposition modeling (FDM), and selective laser sintering (SLS), are reviewed, along with their benefits and drawbacks. Legal and regulatory issues related to the use of 3D printing technology in the medical field are also addressed. The article concludes with an outlook on the future potential of polymer and its composites in 3D printing technology for the medical field. The research findings indicate that 3D printing technology has enormous potential to revolutionize the development and manufacture of medical devices, leading to improved patient outcomes and better healthcare services.

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“…More versatile and automated systems than the above-mentioned ones were proposed in [44][45][46][47][48][49][50]. Among them, Le et al [44] introduced the idea of scanning a single layer of spread powder using a contact image sensor (CIS) installed behind the spreading mechanism (hopper/scraper) to study the powder bed quality levels obtained with different spreading strategies.…”

Section: Introductionmentioning

confidence: 99%

“…The apparatus developed by Snow [47] used the spreading platform and the blade of a commercial system (EOS M280) coupled with a microscope, a camera, and a laser profilometer to respectively analyze the avalanche angle, the surface coverage, and the roughness of a single spread layer. Lupo et al [50] presented a setup with a motorized spreading arm, where a blade with an adjustable inclination angle or roller recoater can be mounted to spread the powder on deposition plates with different depths to mimic different layer thicknesses. A microscope was installed to capture pictures of the powder bed to analyze the spreading uniformity.…”

Section: Introductionmentioning

confidence: 99%

A Novel Apparatus for the Simulation of Powder Spreading Procedures in Powder-Bed-Based Additive Manufacturing Processes: Design, Calibration, and Case Study

Brika,

Brailovski

2023

JMMP

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Powder-bed-based additive manufacturing processes (PBAM) are sensitive to variations in powder feedstock characteristics, and yet the link between the powder properties and process performance is still not well established, which complicates the powder selection, quality control, and process improvement processes. An accurate assessment of the powder characteristics and behavior during recoating is important and must include the flow and packing properties of the powders, which are dependent on the application conditions. To fulfill the need for suitable powder testing techniques, a novel apparatus is developed to reproduce the generic PBAM powder spreading procedure and allow the measurements of the powder bed density, surface uniformity, and spreading forces as functions of the powder characteristics and spreading conditions, including the spreading speed and the type of spreading mechanism. This equipment could be used for research and development purposes as well as for the quality control of the PBAM powder feedstock, as showcased in this paper using a gas-atomized Ti-6Al-4V powder (D10 = 25.3 µm, D50 = 35.8 µm and D90 = 46.4 µm) spread using a rigid blade by varying the recoating speed from 100 to 500 mm/s and the layer thickness from 30 to 100 µm.

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Experimental metrics of the powder layer quality in the selective laser sintering process

Cited by 21 publications

References 36 publications

Effects of Particle Size on Mechanical Properties and Forming Accuracy of Prosopis chilensis Powder/Polyethersulfone Composites Produced via Selective Laser Sintering

Effects of Particle Size on Mechanical Properties and Forming Accuracy of Prosopis chilensis Powder/Polyethersulfone Composites Produced via Selective Laser Sintering

Promising New Horizons in Medicine: Medical Advancements with Nanocomposite Manufacturing via 3D Printing

A Novel Apparatus for the Simulation of Powder Spreading Procedures in Powder-Bed-Based Additive Manufacturing Processes: Design, Calibration, and Case Study

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