Process parameter optimization in polymer powder bed fusion of final part properties in polyphenylene sulfide through design of experiments

Abstract

The Additive Manufacturing (AM) modality of Laser-Based Powder Bed Fusion of Polymers (PBF-LB/P) is an established method for manufacturing semi-crystalline polymers. Like other AM processes, the selection of PBF-LB/P process parameters is critical as it has direct effect on final part properties. While prior research has been predominantly focused on polyamides (e.g., nylon 12), there exists a gap in exploring how process parameters affect higher performance polymers, such as polyphenylene sulfide (PPS). This work aims to explore the effects of PBF-LB/P process parameters on PPS parts printed via PBF-LB/P. While prior PBF-LB/P parameter research primarily relies on evaluating energy input to the system through a single numerical value of energy density, this study investigates the interplay of the print parameters within the energy density equation. To achieve these goals, an analysis was performed on the influence of the laser power, hatch spacing, and beam velocity on ultimate tensile strength (UTS), modulus, and crystallinity of printed parts. A Taguchi L8 array was used in balancing the print parameter combinations allowing for isolation of variance to the specific factors and interactions. Through this approach, print parameter combinations that improved UTS and modulus were identified. Additionally, the study revealed that numerically equivalent energy densities did not lead to equivalent performance, underscoring the significance for including the constitutive process parameters within the energy density equation when establishing process property relationships in printing with PBF-LB/P.