The great interest, within the fields of research and industry, in enhancing the range and functionality of polymer powders for laser powder bed fusion (LB-PBF-P) increases the need for material modifications. To exploit the full potential of the additivation method of feedstock powders with nanoparticles, the influence of nanoparticles on the LB-PBF process and the material behavior must be understood. In this study, the impact of the quantity and dispersion quality of carbon nanoparticles deposited on polyamide 12 particles is investigated using tensile and cubic specimens manufactured under the same process conditions. The nano-additives are added through dry coating and colloidal deposition. The specimens are analyzed by tensile testing, differential scanning calorimetry, polarized light and electron microscopy, X-ray diffraction, infrared spectroscopy, and micro-computed tomography. The results show that minute amounts (0.005 vol%) of highly dispersed carbon nanoparticles shift the mechanical properties to higher ductility at the expense of tensile strength. Despite changes in crystallinity due to nano-additives, the crystalline phases of polyamide 12 are retained. Layer bonding and part densities strongly depend on the quantity and dispersion quality of the nanoparticles. Nanoparticle loadings for CO₂ laser-operated PBF show only minor changes in material properties, while the potential is greater at lower laser wavelengths.

Due to their good material properties (e.g., corrosion and wear resistance, biocompatibility), thermoplastic materials like polyamide 12 (PA12) are interesting for functional coatings on metallic components. To ensure a spatially resolved coating and to shorten the process chain, directed energy deposition of polymer powders by means of a laser beam (DED-LB/P) offers a promising approach. Due to characteristic absorption bands, the use of a thulium fiber laser with a wavelength of 1.94 μm is investigated in a DED-LB/P setup to generate PA12 coatings on stainless steel substrates without the need to add any absorbing additives. The influence of the energy density and powder mass flow was analyzed by infrared thermography. Furthermore, the coatings were characterized by differential scanning calorimetry, laser-scanning-microscopy, optical microscopy and cross-cutting tests. The results in this study demonstrate for the first time the basic feasibility of an absorber-free DED-LB/P process by using a thulium fiber laser. PA12 coatings with a low porosity and good adhesion are achievable. Depending on the application-specific requirements, a trade-off must be made between the density and surface quality of the PA12 coatings. The use of infrared thermography is appropriate for in-situ detection of process instabilities caused by an excessive energy input.

Overcoming the limitations of powder-based additive manufacturing processes is a crucial aspect for the manufacturing of patient-specific sophisticated implants with tailored properties. Within this work, a novel manufacturing process for the fabrication of polymer-based implants is proposed. This manufacturing process is inspired by the laminated object manufacturing technology and is based on using thin films as raw material, which are processed using an ultrafast laser source. Utilizing thin films as a starting material helps to avoid powder contamination during additive manufacturing, thus supporting the generation of internal cavities that can be filled with secondary phases. Additionally, the use of medical materials mitigates the burden of a later certification of potential implants. Furthermore, the ultrafast laser supports the generation of highly resolved structures smaller than the average layer thickness (from 50 to 100 µm) through material ablation. These structures can be helpful to obtain progressive part properties or a targeted stress flow, as well as a specified release of secondary phases (e.g., hydrogels) upon load. Within this work, first investigations on the joining, cutting, and structuring of thin polymer films with layer thickness of between 50 and 100 µm using a ps-pulsed laser are reported. It is shown that thin film sizes of around 50 µm could be structured, joined, and cut successfully using ultrafast lasers emitting in the NIR spectral range.