Almost one-third of the revenues of the Additive Manufacturing (AM) machines market is generated by desktop systems. A new category of such devices are Laser Sintering (LS) machines, in which we can find a few representatives of this group. A growing interest in the use of desktop AM solutions in research and industry is visible, and therefore an evaluation of its capabilities and limitations is desirable. The presented paper focuses on comparing desktop (Sintratec S1; Sinterit Lisa) and industrial (Formiga P110) LS systems. The properties of raw materials were characterized by Scanning Electron Microscopy (SEM) and Differential Scanning Calorimetry (DSC), as well as by determining the Particle Size Distribution (PSD) and static and dynamic flowability of powder. Laser Sintering commercial sets were characterized by their mechanical properties (tensile strength), surface quality (roughness), as well as by their accuracy and porosity (computed tomography). The conducted test showed significant differences, especially in the case of material properties and manufacturing repeatability. The found differences between desktop and industrial LS systems suggest that the use of a low-budget LS system, especially for the research and production of end-use parts, has to take into account its limitations.

The laser-based powder bed fusion of polymers (PBF-LB/P) process often utilizes a blend of powders with varying degrees of degradation. Specifically, for polyamide 12, the traditional reuse schema involves mixing post-processed powder with virgin powder at a predetermined ratio before reintroducing it to the process. Given that only about 15% of the powder is utilized in part production, and powders are refreshed in equal proportions, there arises a challenge with the incremental accumulation of material across build cycles. To mitigate the consumption of fresh powder relative to the actual material usage, this study introduces the incorporation of recycled material into the PBF-LB/P process. This new powder reuse schema is presented for the first time, focusing on the laser sintering process. The characteristics of the recycled powder were evaluated through scanning electron microscopy, differential scanning calorimetry, X-ray diffraction, particle size distribution, and dynamic powder flowability assessments. The findings reveal that waste powders can be effectively reused in PBF-LB/P to produce components with satisfactory mechanical properties, porosity levels, dimensional accuracy, and surface quality.

In this paper, polyamide 12 (PA12) blends with three types of metallic fillers are tested, which differ in the type of material and its’ morphology. Low content mixtures are taken into consideration (0.5, 1.0, 2.0, 5.0 wt%), since a low impact on mechanical properties along with obtaining antibacterial properties are desired. The investigation focuses on filler distribution as well as the influence on microstructural homogeneity of the base material after processing with polymer Laser Sintering. Moreover, the influence of the filler content on the mechanical properties and fracture behaviour were examined. Processability PA12 with bioactive metal fillers was confirmed, and no significant changes in ductile behaviour of PA 12 were observed. An in-depth analysis of the effect of the filler on microstructural homogeneity was conducted. Graphical abstract

We present a comparison of the influence of the conditioning temperature of microspheres made of medical grade poly(L-lactide) (PLLA) and polylactide with 4 wt % of D-lactide content (PLA) on the thermal and structural properties. The microspheres were fabricated using the solid-in-oil-in-water method for applications in additive manufacturing. The microspheres were annealed below the glass transition temperature (T_g), above T_g but below the onset of cold crystallization, and at two temperatures selected from the range of cold crystallization corresponding to the crystallization of the α’ and α form of poly(L-lactide), i.e., at 40, 70, 90, and 120 °C, in order to verify the influence of the conditioning temperature on the sinterability of the microspheres set as the sintering window (SW). Based on differential scanning calorimetry measurements, the SWs of the microspheres were evaluated with consideration of the existence of cold crystallization and reorganization of crystal polymorphs. The results indicated that the conditioning temperature influenced the availability and range of the SWs depending on the D-lactide presence. We postulate the need for an individual approach for polylactide powders in determining the SW as a temperature range free of any thermal events. We also characterized other core powder characteristics, such as the residual solvent content, morphology, particle size distribution, powder flowability, and thermal conductivity, as key properties for successful laser sintering. The microspheres were close to spheres, and the size of the microspheres was below 100 µm. The residual solvent content decreased with the increase of the annealing temperature. The thermal conductivities were 0.073 and 0.064 W/mK for PLA and PLLA microspheres, respectively, and this depended on the spherical shape of the microspheres. The wide angle X-ray diffraction (WAXD) studies proved that an increase in the conditioning temperature caused a slight increase in the crystallinity degree for PLLA microspheres and a clear increase in crystallization for the PLA microspheres.

This paper addresses the critical issue of selecting the optimal mechanical test method for the efficient development of process parameters in Automated Fiber Placement (AFP) technology for manufacturing thermoplastic composite structures reinforced with unidirectional (UD) carbon fibers. Four...