Increased usage of selective laser sintering (SLS) for the production of end-use functional components has generated a requirement of developing new materials and process improvements to improve the applicability of this technique. This article discusses a novel process wherein carbon black was applied to the surface of TPU powder to reduce the laser reflectivity during the SLS process. The printing was carried out with a preheating temperature of 75 °C, laser energy density of 0.028 J/mm², incorporating a 0.4 wt % addition of carbon black to the TPU powder, and controlling the powder layer thickness at 125 μm. The mixed powder, after printing, shows a reflectivity of 13.81%, accompanied by the highest average density of 1.09 g/cm³, hardness of 78 A, tensile strength of 7.9 MPa, and elongation at break was 364.9%. Compared to commercial TPU powder, which lacks the carbon black coating, the reflectance decreased by 1.78%, mechanical properties improved by 33.9%, and there was a notable reduction in the porosity of the sintered product.

Selective laser sintering (SLS) is one of the prominent methods of polymer additive manufacturing (AM). A low-power laser source is used to directly melt and sinter polymer material into the desired shape. This study focuses on the utilization of the low-power laser SLS system to successfully manufacture metallic components through the development of a metal–polymer composite material. In this study, 17-4 PH stainless powders are used and mixed with polyoxymethylene (POM) and high-density polyethylene (HDPE) to prepare the composite powder material. The polymeric mixture is removed during the thermal degreasing process and subsequent sintering results in a solid metallic component. Sinterit Lisa with a 5 W, 808 nm laser source is used to fabricate the green part. For the printing parameters of 140 °C, laser power of 35.87 mJ/mm², and layer thickness of 100 μm, the printed samples achieved a maximum density of 3.61 g/cm³ and a complete shape. After sintering at 1310 °C for 180 min, the tensile strength of the shrunk sample is 605.64 MPa, the hardness is HRC 14.8, the average shrinkage rate is 22%, and the density is 7.57 g/cm³, which can reach 97% of the theoretical density. This process allows the use of a wide range of particle sizes that the usual AM technologies have, making it a low-cost, low-energy-consumption, high-speed AM technology.