Optimization of selective laser sintering process conditions using stable sintering region approach

The optimization of process parameters represents one of the major drawbacks of selective laser sintering (SLS) technology since it is largely empirical and based on performing a series of trial-and-error builds. This approach is time consuming, costly, and it ignores the properties of starting powders. This paper provides new results into the prediction of processing conditions starting from the material properties. The stable sintering region (SSR) approach has been applied to two different polymer-based powders: a polyamide 12 filled with chopped carbon fibers and polypropylene. This study shows that the laser exposure parameters suitable for successful sintering are in a range that is significantly smaller than the SSR. For both powders, the best combination of mechanical properties, dimensional accuracy, and porosity level are in fact, achieved by using laser energy density values placed in the middle of the SSR.