“…The comparison of dimensional accuracy between the RHPA and related biomass composite SLS parts 30–34 is shown in Figure 10. From the comparison in Figure 10, the RHPA parts dimensional accuracy was superior to previously reported materials of wood-plastic composites, i.e., Bamboo flour/Thermoplastic, Cellulose/polyacid composite, and PCPC.Figure 10.Comparison of dimensional accuracy of various SLS biomass–plastic composites manufactured under the same parameter conditions.…”
Section: Resultsmentioning
confidence: 99%
“…Therefore, through combined advantages results of RH content, 10 wt % is represent the optimum ratio in this study. The comparison of dimensional accuracy between the RHPA and related biomass composite SLS parts [30][31][32][33][34] is shown in Figure 10. From the comparison in Figure 10, the RHPA parts dimensional accuracy was superior to previously reported materials of wood-plastic composites, i.e., Bamboo flour/Thermoplastic, Cellulose/polyacid composite, and PCPC.…”
Section: The Influence Of Rh Powder Content On the Properties Of The ...mentioning
The current available wood-plastic materials used for selective laser sintering (SLS) investment casting are often poor in fluidity in molten state, which is not easy to flow out the shell mold. This led to a large amount of residual ash in mold after heating and lowered the quality of the sintered parts. In this article, the Co-Polyamide (Co-PA Hotmelt adhesive) and rice husk powders (RH) were proposed as the feedstock of the rice husk (RH)/CO-PA composite (RHPA) for SLS. CO-PA with good fluidity was used as the matrix and RH powder as the additive materials. This paper aims to optimize the SLS processing parameters and determine the optimal ratio of RHPA parts manufactured by SLS. Through this work, an orthogonal experimental method of five factors and four levels was used to determine the optimum SLS parameters for the RHPA SLS test. The scan spacing, scan speed, laser power, layer thickness, and preheating temperature are chosen as main SLS affecting factors of this study. The synthesis weighted scoring methods were used to conclude the optimal combination of SLS parameters of RHPA i.e., scan spacing = 0.15mm, scan speed = 2m/s, laser power =16W, layer thickness = 0.25 mm and the preheating temperature = 74°C. Moreover, the influence of RH content on the mechanical properties, dimensional accuracy, and the residual ash content of RHPA parts was determined. When the ratio of RH powder on RHPA is 10 wt %, the bending strength of the sintered parts will reach 2 MPa. Besides, the residual ash content of RHPA parts after heating step was lower (1.1881%) and the tolerance level is CT5. Thus, the dimensional accuracy in X, Y, and Z directions of 10 wt % RHPA SLS parts is 99.79%, 98.71%, and 97.9%, respectively; and the surface of casting was smooth and clear details.
“…The comparison of dimensional accuracy between the RHPA and related biomass composite SLS parts 30–34 is shown in Figure 10. From the comparison in Figure 10, the RHPA parts dimensional accuracy was superior to previously reported materials of wood-plastic composites, i.e., Bamboo flour/Thermoplastic, Cellulose/polyacid composite, and PCPC.Figure 10.Comparison of dimensional accuracy of various SLS biomass–plastic composites manufactured under the same parameter conditions.…”
Section: Resultsmentioning
confidence: 99%
“…Therefore, through combined advantages results of RH content, 10 wt % is represent the optimum ratio in this study. The comparison of dimensional accuracy between the RHPA and related biomass composite SLS parts [30][31][32][33][34] is shown in Figure 10. From the comparison in Figure 10, the RHPA parts dimensional accuracy was superior to previously reported materials of wood-plastic composites, i.e., Bamboo flour/Thermoplastic, Cellulose/polyacid composite, and PCPC.…”
Section: The Influence Of Rh Powder Content On the Properties Of The ...mentioning
The current available wood-plastic materials used for selective laser sintering (SLS) investment casting are often poor in fluidity in molten state, which is not easy to flow out the shell mold. This led to a large amount of residual ash in mold after heating and lowered the quality of the sintered parts. In this article, the Co-Polyamide (Co-PA Hotmelt adhesive) and rice husk powders (RH) were proposed as the feedstock of the rice husk (RH)/CO-PA composite (RHPA) for SLS. CO-PA with good fluidity was used as the matrix and RH powder as the additive materials. This paper aims to optimize the SLS processing parameters and determine the optimal ratio of RHPA parts manufactured by SLS. Through this work, an orthogonal experimental method of five factors and four levels was used to determine the optimum SLS parameters for the RHPA SLS test. The scan spacing, scan speed, laser power, layer thickness, and preheating temperature are chosen as main SLS affecting factors of this study. The synthesis weighted scoring methods were used to conclude the optimal combination of SLS parameters of RHPA i.e., scan spacing = 0.15mm, scan speed = 2m/s, laser power =16W, layer thickness = 0.25 mm and the preheating temperature = 74°C. Moreover, the influence of RH content on the mechanical properties, dimensional accuracy, and the residual ash content of RHPA parts was determined. When the ratio of RH powder on RHPA is 10 wt %, the bending strength of the sintered parts will reach 2 MPa. Besides, the residual ash content of RHPA parts after heating step was lower (1.1881%) and the tolerance level is CT5. Thus, the dimensional accuracy in X, Y, and Z directions of 10 wt % RHPA SLS parts is 99.79%, 98.71%, and 97.9%, respectively; and the surface of casting was smooth and clear details.
“…Thus, the sintering window of the powder was (66°C, 97°C). High-quality sintered parts can be manufactured by controlling preheating and processing temperatures within this sintering window range (Idriss et al. , 2023).…”
Purpose
Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source.
Design/methodology/approach
The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated.
Findings
The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties.
Originality/value
This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.
“…Several researchers have conducted studies on the SLS processing of biomass powder composites [14,28,29]. Guo et al [30] from Northeast Forestry University (NEFU) proposed a new environmentally friendly method that involves using cost-effective natural agricultural and forestry waste as a feedstock for SLS.…”
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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