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Additive manufacturing (AM) of thermoplastic polymers for powder bed fusion processes typically requires each layer to be fused before the next can be deposited. The purpose of this paper is to present a volumetric AM method in the form of deeply penetrating radio frequency (RF) radiation to improve the speed of the process and the mechanical properties of the polymer parts.

The focus of this study was to demonstrate the volumetric fusion of composite mixtures containing polyamide (nylon) 12 and graphite powders using RF radiation as the sole energy source to establish the feasibility of a volumetric AM process for thermoplastic polymers. Impedance spectroscopy was used to measure the dielectric properties of the mixtures as a function of increasing graphite content and identify the percolation limit. The mixtures were then tested in a parallel plate electrode chamber connected to an RF generator to measure the heating effectiveness of different graphite concentrations. During the experiments, the surface temperature of the doped mixtures was monitored.

Nylon 12 mixtures containing between 10% and 60% graphite by weight were created, and the loss tangent reached a maximum of 35%. Selective RF heating was shown through the formation of fused composite parts within the powder beds.

The feasibility of a novel volumetric AM process for thermoplastic polymers was demonstrated in this study, in which RF radiation was used to achieve fusion in graphite-doped nylon powders.

Powder bed additive manufacturing processes are widespread due to their many technical and economic advantages. Nevertheless, the disposal of leftover powder poses a problem in terms of process sustainability. The purpose of this paper is to provide an alternative solution to recycle waste PA12 powder from HP multi jet fusion. In particular, the opportunity to use this material as a dispersion in three-dimensional (3D) printed clay is investigated.

A commercial fused deposition modelling printer was re-adapted to extrude a viscous paste composed of clay, PA12 and water. Once printed, parts were dried and then put in an oven to melt the polymer fraction. Four compositions with different PA12 concentration were studied. First, the extrudability of the paste was observed by testing different extrusion lengths. Then, the surface porosities were evaluated through microscopical observations of the manufactured parts. Finally, benchmarks with different geometries were digitalised via 3D scanning to analyse the dimensional alterations arising at each stage of the process.

Overall, the feasibility of the process is demonstrated. Extrusion tests revealed that the composition of the paste has a minor influence on the volumetric flow rate, exhibiting a better consistency in the case of long extrusions. The percentage of surface cavities was proportional to the polymer fraction contained in the mix. From dimensional analyses, it was possible to conclude that PA12 reduced the degree of shrinkage during the drying phase, while it increased dimensional alterations occurring in the melting phase. The results showed that the dimensional error measured on the z-axis was always higher than that of the XY plane.

The method proposed in this paper provides an alternative approach to reuse leftover powders from powder bed fusion processes via another additive manufacturing process. This offers an affordable and open-source solution to companies dealing with polymer powder bed fusion, allowing them to reduce their environmental impacts while expanding their production.

The paper presents an innovative additive manufacturing solution for powder reuse. Unlike the recycling methods in the body of literature, this solution does not require any intermediate transformation process, such as filament fabrication. Also, the cold material deposition enables the adoption of very inexpensive extrusion equipment. This preliminary study demonstrates the feasibility and the benefits of this process, paving the way for numerous future studies.

This study aims to demonstrate for the first time that the cheap, commodity polymer, poly(propylene), can be successfully processed using high speed sintering, and that it can be recycled several times through the process, with little to no detriment to either the polymer itself or the parts obtained. This is significant as a step towards the realisation of high speed sintering as a technology for high-volume manufacturing.

A poly(propylene) powder designed for laser sintering was used to build parts on a high speed sintering machine. The unsintered powder was then collected and reused. Repeating this process allowed creation of seven generations of aged powder. A variety of characterisation techniques were then used to measure polymer, powder and part properties for each generation to discern any effects arising from ageing in the machine.

It was found that poly(propylene) could be used successfully in high speed sintering, albeit with a low build success rate. Increased powder age was found to correlate to an increase in the build success rate, changes in microscopic and bulk powder properties and improvement to the dimensional accuracy of the parts obtained. By contrast, no discernible correlations were seen between powder age and polymer molecular weight, or between powder age and the tensile properties of parts.

This is the first report of the use of poly(propylene) in high speed sintering. It is also first study regarding powder recyclability in high speed sintering, both in general and using poly(propylene) specifically.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

This paper aims to present a survey concerning the accuracy of thermoplastic polymeric parts fabricated by additive manufacturing (AM). Based on the scientific literature, the aim is to provide an updated map of trends and gaps in this relevant research field. Several technologies and investigation methods are examined, thus giving an overview and analysis of the growing body of research.

Permutations of keywords, which concern materials, technologies and the accuracy of thermoplastic polymeric parts fabricated by AM, are used for a systematic search in peer-review databases. The selected articles are screened and ranked to identify those that are more relevant. A bibliometric analysis is performed based on investigated materials and applied technologies of published papers. Finally, each paper is categorised and discussed by considering the implemented research methods.

The interest in the accuracy of additively manufactured thermoplastics is increasing. The principal sources of inaccuracies are those shrinkages occurring during part solidification. The analysis of the research methods shows a predominance of empirical approaches. Due to the experimental context, those achievements have consequently limited applicability. Analytical and numerical models, which generally require huge computational costs when applied to complex products, are also numerous and are investigated in detail. Several articles deal with artificial intelligence tools and are gaining more and more attention.

The cross-technology survey on the accuracy issue highlights the common critical aspects of thermoplastics transformed by AM. An updated map of the recent research literature is achieved. The analysis shows the advantages and limitations of different research methods in this field, providing an overview of research trends and gaps.

Orange peel formation remains to be understood clearly because it is difficult to directly observe a laser-sintered process in a partcake. Therefore, this study aims to provide insight into the orange peel formation mechanism through the nondestructive observation of laser-sintered specimens and their surrounding powders.

This study observed polyamide 12 powder in the vicinity of a laser-sintered specimen via X-ray computed tomography (CT) scanning. The specimen for nondestructive observation was 3D modeled in a hollow box using 3D CAD software. The boxes built using a laser-sintering system contained unsintered surrounding powder and sintered specimens. The box contents were preserved even after the boxes were removed from the partcake. After X-ray CT scanning, the authors broke the boxes and evaluated the unevenness formed on the specimen surface (i.e. the orange peel evaluation).

Voids (not those in sintered parts) generated in the powder in the vicinity of the specimen triggered the orange peel formation. Voids were less likely to form in the build with a 178.5° powder bed than in the build with a 173.5° powder bed. Similarly, the increment in laser energy density effectively suppressed void formation, although there was a tradeoff with overmelting. Thin-walled parts avoided void growth and made the orange peel less noticeable.

To the best of the authors’ knowledge, this study is the first to observe and understand the relationship between voids generated in the powder in the vicinity of sintered parts and orange peel formation.

Selective laser sintering (SLS) is an essential technology in the field of additive manufacturing. However, SLS technology is limited by the traditional point-laser sintering method and has reached the bottleneck of efficiency improvement. This study aims to develop an image-shaped laser sintering (ISLS) system based on a digital micromirror device (DMD) to address this problem. The ISLS system uses an image-shaped laser light source with a size of 16 mm × 25.6 mm instead of the traditional SLS point-laser light source.

The ISLS system achieves large-area image-shaped sintering of polymer powder materials by moving the laser light source continuously in the x-direction and updating the sintering pattern synchronously, as well as by overlapping the splicing of adjacent sintering areas in the y-direction. A low-cost composite powder suitable for the ISLS system was prepared using polyether sulfone (PES), pinewood and carbon black (CB) powders as raw materials. Large-sized samples were fabricated using composite powder, and the microstructure, dimensional accuracy, geometric deviation, density, mechanical properties and feasible feature sizes were evaluated.

The experimental results demonstrate that the ISLS system is feasible and can print large-sized parts with good dimensional accuracy, acceptable geometric deviations, specific small-scale features and certain density and mechanical properties.

This study has achieved the transition from traditional point sintering mode to image-shaped surface sintering mode. It has provided a new approach to enhance the system performance of traditional SLS.

This study aims to investigate the effect of the material thickness and build orientation on the mass transfer of low molecular weight substances through polyamide 12 (PA12) structures produced by laser sintering (LS).

Disc-shaped PA12 sheets having a nominal thickness ranging from 700 to 2,000 µm were built in horizontal, vertical and diagonal orientations and their permeation properties to oxygen and water vapor were measured. The structural properties of the sheets were examined by X-ray micro-computed tomography, differential scanning calorimetry and polarized light microscopy.

All the LS sheets that were investigated had water vapor and oxygen permeation coefficients that are in the range of those of PA12 produced by traditional manufacturing technologies. Despite significant differences in the porosity characteristics, the permeation properties of sheets built in different orientations were similar. The pores seem to have no measurable effect on the mass transfer rates in the sheets, and the transport processes seem to predominantly follow the rules of a regular solution-diffusion mechanism. The results showed a non-significant trend toward thickness-dependent permeation coefficients, which agrees with the observed differences in the crystal structures of the sheets.

The results are an important basis for the qualification of LS technology for direct manufacturing in applications requiring special barrier performance.

This study provides new information on mechanisms of mass transport through LS PA12 and the effect of the material thickness and build orientation. Furthermore, the results enhance understanding of the structural properties of thin polymeric sheets produced by LS.

Additive manufacturing (AM) can reduce the process supply chain and encourage manufacturing innovation in remote or austere environments by producing an array of replacement/spare parts from a single raw material source. The wide variety of AM technologies, materials, and potential use cases necessitates decision support that addresses the diverse considerations of deployable manufacturing. The paper aims to discuss these issues.

Semi-structured interviews with potential users are conducted in order to establish a general deployable AM framework. This framework then forms the basis for a decision support tool to help users determine appropriate machines and materials for their desired deployable context.

User constraints are separated into process, machine, part, material, environmental, and logistical categories to form a deployable AM framework. These inform a “tiered funnel” selection tool, where each stage requires increased user knowledge of AM and the deployable context. The tool can help users narrow a database of candidate machines and materials to those appropriate for their deployable context.

Future work will focus on expanding the environments covered by the decision support tool and expanding the user needs pool to incorporate private sector users and users less familiar with AM processes.

The framework in this paper can influence the growth of existing deployable manufacturing endeavors (e.g. Rapid Equipping Force Expeditionary Lab – Mobile, Army’s Mobile Parts Hospital, etc.) and considerations for future deployable AM systems.

This work represents novel research to develop both a framework for deployable AM and a user-driven decision support tool to select a process and material for the deployable context.

The purpose of this paper is to elucidate the extent to which the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion influence the top surface topographies of laser sintered polyamide (PA12) components.

Laser sintered specimens were manufactured at varying laser parameters in accordance with a full factorial design of experiments. Focus variation microscopy was used to ascertain insight into their top surface heights and peak/valley distributions. Subsequently, regression expressions were generated to model the former with respect to applied laser parameters. Auxiliary experimental analysis was also performed to validate the proposed mechanisms and statistical models.

Within the parameter range tested, this work found the root mean square (S_q) and skewness (S_sk) roughness responses of laser sintered PA12 top surfaces to be inversely related to one another, and both also principally influenced by beam spacing. Furthermore, it was demonstrated that using optimised laser parameters (to promote polymer melt dispersion) and building without finish layers (to avert subsequent powder particle adhesion) reduced the mean S_q roughness of resultant topographies by 30.8% and 47.9% relative to standard laser sintered PA12 top surfaces, respectively.

The scope to which laser sintered PA12 top surfaces can be modified was highlighted.

This research demonstrated the impact the mechanisms of polymer melt viscous flow and finish layer powder particle adhesion have on laser sintered PA12 top surfaces.