Selective laser sintering (SLS) of thermoplastic materials is an additive manufacturing process that overcomes the boundary between prototype construction and functional components. This technique also meets the requirements of traditional and established production processes. Crystallization behavior is one of the most critical properties during the cooling process and needs to be fully understood. Due to the huge influence of crystallization on the mechanical and thermal properties, it is important to investigate this process more closely. A commercial SLS polyamide (PA12) powder was measured with differential scanning calorimetry (DSC) to model a wider temperature range. To model isothermal crystallization between 160 and 168 °C, the Avrami model was used to determine the degree of crystallization. For non-isothermal crystallization between 0.2 and 20 K/min, different models were compared including the Ozawa, Jeziory, and Nakamura equations.

The needle-like Al₂O₃–ZnO nanowire hybrid filler endows polymer composites with high thermal conductivity, mechanical and thermal properties.

To make better use of fiber reinforced polymer composites in automotive applications, a clearer knowledge of its interfacial properties under dynamic and thermal loadings is necessary. In the present study, the interfacial behavior of glass fiber reinforced polypropylene (PP) composites under different loading temperatures and strain rates were investigated via molecular dynamics simulation. The simulation results reveal that PP molecules move easily to fit tensile deformation at higher temperatures, resulting in a lower interfacial strength of glass fiber–PP interface. The interfacial strength is enhanced with increasing strain rate because the atoms do not have enough time to relax at higher strain rates. In addition, the non-bonded interaction energy plays a crucial role during the tensile deformation of composites. The damage evolution of glass fiber–PP interface follows Weibull’s distribution. At elevated temperatures, tensile loading is more likely to cause cohesive failure because the mechanical property of PP is lower than that of the glass fiber–PP interface. However, at higher strain rates, the primary failure mode is interfacial failure because the strain rate dependency of PP is more pronounced than that of the glass fiber–PP interface. The relationship between the failure modes and loading conditions obtained by molecular dynamics simulation is consistent with the author’s previous experimental studies.

In order to understand the absorption characteristic, a ray trace model is developed by taking into account the reflection, absorption and refraction. The ray paths are resolved on a sub-powder grid. For validation, the simulation results are compared to analytic solutions of the irradiation of the laser beam onto a plain surface. In addition, the absorptance, reflectance and transmittance of PA12 powder layers measured by an integration sphere setup are compared with the numerical results of our model. It is shown that the effective penetration depth can be lower than the penetration depth in bulk material for polymer powders and, therefore, can increase the energy density at the powder bed surface. The implications for modeling of the selective laser sintering (SLS) process and the processability of fine powder distributions and high powder bed densities are discussed.

In this research, the influences of filler content and filler particle size on the flow-hardening behavior were investigated by a measuring mixer. In order to more reliably assess the observed rheological behavior, isothermal differential scanning calorimetry (DSC) measurements were employed to study the curing kinetics of the compounds. The measured data can be fitted well with Kamal-Sourour’s model modified by the diffusion correlation according to Chern and Poehlein. After that, the influence of filler content and size on the kinetic parameters are presented discussed. The results show that the ultimate glass transition temperature is significantly lower for pure epoxy resin (EP) than for compounds filled with surface-treated glass beads, which have an essential effect on the diffusion-controlled reaction at different curing temperatures. For the surface-treated glass beads used in this study, the reaction speed in the early curing stage is accelerated by increasing filler content or decreasing of filler size. In the later curing stage, the reaction speeds of compounds with higher filler content or smaller fillers reduce more quickly. The study of reaction kinetics indicates that the activation energy Ea₁, Ea₂, the reaction order m, and n are affected differently by varying filler content and size.

In this study, the feasibility of co-grinding and the subsequent thermal rounding to produce spherical polymer blend particles for selective laser sintering (SLS) is demonstrated for polybutylene terephthalate (PBT) and polycarbonate (PC). The polymers are jointly comminuted in a planetary ball mill, and the obtained product particles are rounded in a heated downer reactor. The size distribution of PBT–PC composite particles is characterized with laser diffraction particle sizing, while the shape and morphology are investigated via scanning electron microscopy (SEM). A thorough investigation and characterization of the polymer intermixing in single particles is achieved via staining techniques and Raman microscopy. Furthermore, polarized light microscopy on thin film cuts enables the visualization of polymer mixing inside the particles. Trans-esterification between PBT and PC during the process steps is investigated via vibrational spectroscopy and differential scanning calorimetry (DSC). In this way, a new process route for the production of novel polymer blend particle systems for SLS is developed and carefully analyzed.