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Novel process for suppressing orange peel formation in polymer laser sintering through pretreatment with low-power laser irradiation

Ryuichi Kobayashi (Tokyo Metropolitan Industrial Technology Research Institute, Koto-ku, Japan and Tokyo Metropolitan University, Hino, Japan)
Takashi Kigure (Tokyo Metropolitan Industrial Technology Research Institute, Koto-ku, Japan)
Ming Yang (Tokyo Metropolitan University, Hino, Japan)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 23 September 2021

Issue publication date: 18 March 2022

126

Abstract

Purpose

This paper aims to describe a new process for suppressing the formation of orange peel, which is a polymer laser sintering (LS) process error.

Design/methodology/approach

The target for controlling the suppression of orange peel is securing the contact between the molten polymer and the surrounding powder. The authors set the powder bed temperature closer to the melting temperature than that for a typical LS. Alternatively, the authors use a low-power laser to irradiate the powder bed surrounding the parts being built. The surface finish of the built parts was evaluated using a three-dimensional scanner.

Findings

Both approaches were effective in suppressing orange peel. From the viewpoint of reusability of the used powder, the process that includes low-power laser irradiation is practical. The presence or absence of contact between the surrounding powder and the molten polymer determines whether the orange peel is formed.

Research limitations/implications

The authors have not tested orange peel suppression for complex shapes.

Originality/value

The authors have demonstrated a concrete process that can suppress orange peel formation even for powders with low melt-flow rates. Furthermore, a mechanism for the formation/suppression of orange peel based on the experimental results was proposed.

Keywords

Acknowledgements

The authors would like to thank Enago (www.enago.jp) for the English language review. This work was supported by JSPS KAKENHI Grant Number 19K14867.

Citation

Kobayashi, R., Kigure, T. and Yang, M. (2022), "Novel process for suppressing orange peel formation in polymer laser sintering through pretreatment with low-power laser irradiation", Rapid Prototyping Journal, Vol. 28 No. 3, pp. 505-513. https://doi.org/10.1108/RPJ-03-2021-0068

Publisher

:

Emerald Publishing Limited

Copyright © 2021, Emerald Publishing Limited

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