Prediction of SLS parts properties using reprocessing powder

Purpose Owing to the operating principle of powder bed fusion processes, selective laser sintering (SLS) requires effective management of the mixture ratio of processed material previously exposed to the high temperatures of processing with new virgin material. Therefore, this paper aims to fully understand the effect that the successive reprocessing has in the powder material and to evaluate its influence on the properties of SLS parts produced at different building orientations. Design/methodology/approach Polyamide 12 material with 0%, 30% and 50% of virgin powder and parts produced from them were studied through five consecutive building cycles and their mass, mechanical, thermal and microstructural properties were evaluated. Then, the experimental data was used to validate a theoretical algorithm of prediction capable to define the minimum amount of virgin powder to be added on the processed material to produce parts without significant loss of properties. Findings Material degradation during SLS influences the mass and mechanical properties of the parts, exhibiting an exponential decay property loss until 50% of the initial values. The theoretical algorithms of reprocessing proved the appropriateness to use a mixture of 30% of virgin with 70% of processed material for the most common purposes. Practical implications This paper validates a methodology to define the minimum amount of virgin material capable to fulfil the operational specifications of SLS parts as a function of the number of building cycles, depending on the requirements of the final application. Originality/value The use of theoretical models of prediction allows to describe the degradation effects of SLS materials during the sintering, ensuring the sustainable management of the processed powder and the economic viability of the process.