SELECTIVE LASER

SINTERING PRINTERS

Production thermoplastic parts with ProX™

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and sPro™ SLS printers

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Microparts with a structural resolution of 12 have been

generated by selective laser sintering. The technique includes sintering under conditions of

vacuum or reduced shield gas pressures. In a novel set-up the material is processed by a Switched 1064nm Nd-YAG laser after a special raking procedure. The procedure allows the

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work pieces to be generated from powders of high melting metals like tungsten as well as

lower melting metals like aluminium and copper.

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This paper investigates thermal modelling of the selective laser sintering process for amorphcus

polycarbonate powders. The aim is to develop a simulation for process accuracy and control which are key areas of developement for the new layer manufacturing rapid prototyping technologies. A state-of-the-art adaptive mesh 20 finite difference code is used simultaneously to consider heating and sintering and its results compared with a classical moving heat source model and with experiments. The analysis shows that the change of material thermal properties with temperature and particularly with position as densification takes place must be included for accurate prediction of both densification and of the phenomenon known as 'bonus 2'. The work forms a basis for moving to a 3D simulation.

The success of SLS as a rapid prototyping and rapid manufacturing technology results

mainly to the possibility to process almost any type of materials (polymers, glass-filled

nylon, metal and composites) to accommodate multiple applications throughout the

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manufacturing process, but high density is desired for the production of functional metallic

parts.

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Selective Laser Sintering (SLS) is close to be accepted as a production technique (Additive Manufacturing).However, one problem limiting employment of SLS for additive manufacturing in a wide-ranging industrial scope is the narrow variety of applicable polymers.

Layer Manufacturing (LM) technologies like Selective Laser Sintering (SLS) were developed

in the late 80’s as techniques for Rapid Prototyping (RP). Today, SLS - as well as its derived

technology Selective Laser Melting (SLM) - is used as well for prototyping, tooling and

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manufacturing purposes. This widening of applications is caused mainly by the possibility to

process a large variety of materials, resulting in a broad range of physical and mechanical

properties.

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