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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Hybrid of multi‐dimensional fillers for thermally enhanced polyamide 12 composites fabricated by selective laser sintering

Abstract Selective laser sintering (SLS) is an additive manufacturing technology that can provide a novel strategy to manufacture complex polymer‐based composites with tailored properties. In this study, polyamide 12 (PA12) composite powders based on Al 2 O 3 , boron nitride (BN), and carbon nanotubes (CNTs) were prepared via a two‐step mixing approach. Morphology characterization techniques indicated that the fillers were uniformly dispersed in the PA12 matrix as expected. Under the optimum 3D‐printing parameters, the fabrication of SLS parts with high filler loading could be obtained. With 40 wt% Al 2 O 3 , 8 wt% BN, and 2 wt% CNT hybrid fillers, the thermal conductivity of PA12 composites could reach 1.09 W/mK. It could be attributed to the synergistic effect of multi‐dimensional fillers to form dense and continuous thermal conduction paths. The factors influencing the performance of PA12 composites such as melting and crystallization behaviors, dielectric properties, and mechanical properties were also discussed. The results show that these composites have favorable dielectric and mechanical properties. Overall, the PA12 composites fabricated by SLS technology in this study exhibit excellent thermal management ability.

Yuan, Yue↗
NASA NTRS2019

Manufacturing of Thermoset Polyimide Composites by Laser Sintering

Selective Laser Sintering (SLS) is an additive manufacturing technique that builds 3D models layer by layer using a laser to selectively melt cross sections in powdered polymeric materials, following sequential slices of the computer-aided design (CAD) model. SLS generally uses thermoplastic polymeric powders such as polyamides. The resultant 3D-printed objects are often weaker in their strength compared to traditionally processed materials, due to their higher porosity. This paper described the process development of using melt-processable imide oligomers terminated with reactive 4-phenylethynylphthalic anhydride (4-PEPA) to conduct laser sintering (LS). The first successful 3D-printing of high temperature RTM370 thermoset polyimide carbon fiber composites were further post-cured to promote additional crosslinking for achieving higher temperature (T g = 370°C) capability. Another novel imide oligomer, RTM385-SLS, formulated with a complex melt viscosity [ƞ*] of ~104-105 poise is also suitable for LS. RTM385-SLS resin powder was mixed with 20-25% of hexagonal boron nitride (h-BN) and subjected to LS to print out “Green” specimens which could be further post-cured to afford a thermally conductive but electrically insulating composites with high T g of 385 °C. The cured composite specimens were then subjected to mechanical testing, thermal conductivity and porosity measurements as well as SEM characterization.

additive Manufacturing↗
DOE OSTI2022

Printability and Mechanical Properties of Polyethylene and Polyethylene/Nylon Blend Parts Made by Selective Laser Sintering

Improving the printability of polyethylene powder in selective laser sintering is of keen interest for the additive manufacturing community. Work to increase the variety of available feedstocks still must be done, as Nylon powder still constitutes a huge majority of all feedstocks used for selective laser sintering. Polyethylene is particularly of interest because it is a cheap, commodity polymer. Although some commercially available polyethylene powders exist, choosing one of these means the user is restricted to the specific polymer properties that those powders possess. Developing a reproducible processing parameter regime for polyethylene that exhibits other useful properties, such as very high densities or molecular weights, requires a uniquely tailored set of processing parameters. Particular emphasis will be placed on processing parameters that result in improved mechanical properties, as well as the possibility of successfully making SLS parts from polyethylene blends, e.g. polyethylene/Nylon blends.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Selective laser sintering and spark plasma sintering of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide ceramics

Abstract Two advanced manufacturing processes, spark plasma sintering (SPS) and selective laser sintering (SLS), have been developed for synthesis of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide (CCC) via reactive sintering of a powder mixture of constitute monocarbides. X‐ray diffraction analysis confirmed that the single‐phase CCC can be formed by both SPS and SLS. While a homogenous microstructure with uniform metal element distributions was developed during SPS, three‐layer microstructures with a thin TiC‐rich layer and two TaC‐rich layers along with a TiO 2 ‐rich surface layer containing W nanoparticles were formed during SLS. In addition, cellular structures with W, Zr, and Ti element segregation and dislocations on cell boundaries were observed in the SLS‐CCC sample, indicating the effect of nonequilibrium conditions on microstructure formation during laser melting followed by rapid cooling and solidification process. Compared to the SPS‐CCC sample, the SLS‐CCC showed enhanced hardness and reduced thermal conductivity, which may be related to their unique cellular structures.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Developing New Polymeric Powder Feedstocks for Selective Laser Sintering: Emphasizing Particle Size and Shape

Although selective laser sintering is considered a major player in the additive manufacturing community, significant limitations exist when it comes to processing the polymeric powder feedstocks in the laser sintering machine. While these limitations – such as inadequate and uneven heating and complex thermal phenomena leading to curling and shrinkage – cannot be ignored and are being addressed in the community, it is also vitally important to turn our attention to the expansion of commercially available powder feedstocks. A major drawback of SLS is the lack of available feedstocks. At Los Alamos National Laboratory, a primary desire for advancement in the manufacturing or development of new feedstocks lies in the nuclear weapons applications program. New feedstocks with greater thermal stability and performance would provide the opportunity for insertion of production parts, rather than just prototype parts. Additionally, the ability to print with so-called commodity polymers like polyethylene and polypropylene poses great economic advantages for prototyping and production of large batches of parts. However, a gap exists between the Lab’s needs and what is commercially available – a gap which could be filled by collaboration with the broader industrial sector. Furthermore, connecting with and building relationships with industry partners allows for greater control and input in the developmental process of new powders. This would provide reliable feedstocks, improved quality assurance, and overall higher performance of processes across the additive manufacturing community.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Direct selective laser sintering of hexagonal barium titanate ceramics

Abstract A direct selective laser sintering (SLS) process was combined with a laser preheating procedure to decrease the temperature gradient and thermal stress, which was demonstrated as a promising approach for additive manufacturing of BaTiO 3 ceramics. The phase compositions in BaTiO 3 ceramics fabricated by SLS were investigated by X‐ray and neutron diffractions. The surface morphologies and cross‐section microstructures were characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). A dense hexagonal h‐BaTiO 3 layer was formed on the surface and extended to a depth of 500 μm, with a relative density higher than 97% and absence of pores or microcracks. SLS resulted in the formation of the high‐temperature phase, h‐BaTiO 3 , which was retained at room temperature possibly due to the high cooling rate. The grain boundaries of SLSed h‐BaTiO 3 ceramics consist of a Ti‐rich secondary phase. Compared with that of the pressureless sintered t‐BaTiO 3 ceramics, the Vickers hardness of SLSed h‐BaTiO 3 is 70% higher.

Zhang, Xiang↗
DOE OSTI2022

Selective Laser Sintering of High-Temperature Thermoset Polymer

Thermoplastic materials such as PA12 and PA6 have been extensively employed in Selective Laser Sintering (SLS) 3D printing applications due to their printability, processability, and crystalline structure. However, thermoplastic-based materials lack polymer inter-chain bonding, resulting in inferior mechanical and thermal properties and relatively low fatigue behavior. Therefore, 3D printing of high-performance crosslinked thermosets using SLS technology is paramount to pursue as an alternative to thermoplastics. In this work, a thermoset resin was successfully 3D printed using SLS, and its thermal stability of printed parts after a multi-step post-curing process was investigated. Dimensionally stable and high glass transition temperature (Tg: ~300 °C) thermoset parts were fabricated using SLS. The polymer crosslinking mechanism during the printing and curing process was investigated through FTIR spectra, while the mechanical stability of the SLS 3D-printed thermoset was characterized through compression tests. It is found that 100% crosslinked thermoset can be 3D printed with 900% higher compressive strength than printed green parts.

Hassan, Md Sahid (ORCID:0000000304665395)↗
DOE OSTI2023

Method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering

The invention is directed to a method of controlled conversion of thermosetting resins and additive manufacturing thereof by selective laser sintering. Partial curing of a thermosetting formulation can be used to increase the T g of the resin and minimize the additional cure needed to cross-link a printed object. After printing, the partially cured material is finally cured via a slow temperature ramp maintained just below the material's evolving T g .

Campbell, C. Garrett↗
DOE OSTI2022

Low-temperature selective laser sintering 3D printing of PEEK-Nylon blends: Impact of thermal post-processing on mechanical properties and thermal stability

Herein, a high-performance polymer (HPP) (polyether ether ketone, PEEK) blended with a commercial low-temperature polymer (polyamide 12, PA-12) was fabricated using a low-temperature selective laser sintering (SLS) 3D printer. Different post-processing heat treatments were implemented after fabrication to tune the thermal and mechanical properties of printed blends. The specific mechanical modulus of the blend was increased up to 79% in comparison to printed PA-12 samples with heat treatment. Additionally, the thermal resistance of the treated blends greatly exceeded the properties observed using PA-12 alone. This research proposes a methodology to fabricate and engineer HPP using desktop SLS printers through a secondary lower melting temperature material and heat treatments.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Selective Laser Sintering of Polyolefins

Polyolefins are some of the most produced and used polymers around the globe. They are semi-crystalline thermoplastic polymers known for their low production cost while still exhibiting good mechanical properties and chemical resistance. These polymers are often used in a variety of manufacturing processes, including 3D printing or additive manufacturing (AM). However, due to their semi-crystalline nature, there are often issues with using polyolefins in AM processes (for example, shrinkage leading to dimensional instabilities). One example of an AM process for which polyolefins are of interest is selective laser sintering (SLS), where printability depends on the powdered material’s morphology, flowability, and size. Due to the inherent properties of polyolefins, there are a variety of issues surrounding their use in the SLS process. This paper aims to review the basics of SLS as well the current state of SLS printing of a few polyolefins and what challenges that would need to be overcome to print with these polyolefins.

36 MATERIALS SCIENCE↗
NASA NTRS2019

Evaluation of an Alternate Method for Determining Yield Strength Offset Values for Selective Laser Sintered Polymeric Materials

Due to the unique characteristics of Additively Manufactured (AM) polymeric materials, typical mechanical strength characterization methods such as those commonly used for traditionally-processed polymers or composite materials can produce results that do not accurately represent material capabilities. In order to characterize mechanical properties of these materials, new test and analysis methods are required. As part of the National Aeronautics and Space Administration (NASA) Advanced Composites Project (ACP), Boeing has evaluated true yield testing as an alternative or complimentary test to 0.2% offset yield testing for determining appropriate yield strength values of polymer materials. Previous testing has shown high strain, low modulus polymer materials such as selective laser sintered (SLS) Nylon 11 at elevated temperatures produce large variations in yield strength. The true yield test method was successful in finding the applied strain level when yield commences and appears to offer an increase in data robustness.

Henry, Chelsey↗
DOE OSTI2024

Literature Review of Recycling Polypropylene and Polyamide 12 Powders for Selective Laser Sintering

Additive manufacturing (AM) is the creation of three-dimensional parts by adding material layer-by-layer based on two dimensional “slices” of a CAD file, without molds or tooling. AM has broken the relationship between part complexity and manufacturing cost. As a general rule, for conventional manufacturing, the more complex the part produced, the more costly its manufacturing. For example, in the production of a bracket for a satellite, moving from conventional manufacturing to AM allowed the part to be consolidated from 4 parts to just one, as well as reducing the weight of the part by 35%. A further benefit, AM can be more cost effective for small lot sizes. To illustrate, consider a case study of white board marker caps presented by Klahn et al. The cost to produce 1,000 units of a new design using SLS was about an order of magnitude lower than conventional manufacturing, as shown in Figure 1.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Effect of lattice orientation on compressive properties of selective laser sintered nylon lattice coupons

As AM lattices become more popular in medical devices, it is important to consider how lattice design parameters affect the mechanical integrity and performance of a device. This research investigated the effect of lattice orientation on the compressive mechanical response of five common lattice geometries: Hexagonal Honeycomb (Hex), Diamond, Voronoi Tessellation Method (VTM), sheet-based Gyroid, and Face-Centered-Cubic (FCC). Samples were tested at two relative densities and eight orientations, printed in Nylon 12 (PA2200) on an EOS P396. The mechanical response was compared to simulated finite element analysis (FEA) response for Hex and FCC lattices. Hex lattices displayed significant orientation dependance. Diamond lattices demonstrated some orientation dependance when at a lower relative density. Gyroid, FCC, and VTM all displayed minimal orientation dependance. Increasing lattice relative density appeared to reduce anisotropy among tested orientations of all lattice geometries except Hex. FEA simulations were able to produce a trend response that matched the mechanical response trends based on the investigated orientations. Furthermore, these results support the need for multi axial lattice mechanical test considerations. It also bolsters the need for lattice FEA models to have a sufficient comparator when identifying “worst-case” lattice test scenarios.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Polymer Composites Reinforced by Carbon-Allotrope Fillers for Selective Laser Sintering (SLS) - A Review

The limited commercial availability of applicable polymer powders has hindered the widespread implementation of SLS as a legitimate manufacturing method. This is partly due to the mechanism of SLS, which requires powders to meet rigid specifications if processing is to be successful. Furthermore, powders that do meet requirements are often incapable of producing quality, high-performance parts. Academic and industrial research has focused on composite development to overcome this problem. The incorporation of fillers including calcium carbonate, molybdenum disulfide, and aluminum have all been found to influence the processing behavior of PA12 powder and ultimately, the properties of the final part.3-5 Here, the thermal and mechanical properties of sintered composite parts produced using polymer powders reinforced by various carbon-based fillers is discussed.

36 MATERIALS SCIENCE↗