<p>Laser based powder bed fusion of polymers (PBF-LB/P) is an additive manufacturing process that produces parts by selectively fusing a polymer powder bed using laser irradiation. PBF-LB/P conducted at a powder bed temperature below the crystallization temperature measured by DSC, referred to as the low-temperature process, offers advantages such as reduced thermal degradation of the material and an expanded range of compatible materials. However, the shrinkage behavior of low-temperature process significantly differs from that of conventional PBF-LB/P due to differences in the preheating temperature of the powder bed. Consequently, this hinders the direct application of conventional shape compensation strategies, and there is a need for a dedicated deformation prediction model. Laser based powder bed fusion of metal (PBF-LB/M) exhibits similar characteristics, that crystallization is initiated immediately after the heating beam has passed, and several commercial simulation tools are available to predict the deformation. Nevertheless, it remains unclear whether the approaches developed for PBF-LB/M can be directly applied to low-temperature polymer process, given the large differences in the material properties. This study investigated stress evolution and deformation induced by shrinkage during the build process in low-temperature process, with emphasis on identifying the similarities and differences relative to PBF-LB/M. The results showed that the residual stresses after low-temperature process were substantially lower than those in PBF-LB/M. In contrast, the strain and resulting deformation were more pronounced in low-temperature process. The findings indicated that deformation should be the primary focus in the development of prediction models for low-temperature process rather than the residual stress-centric prediction models typically used for PBF-LB/M.</p>

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Consideration of part deformation in PBF-LB/P without relying on the conventional process window: a low-temperature process below the crystallization temperature measured by DSC

  • Takashi Kigure,
  • Yuki Yamauchi,
  • Toshiki Niino

摘要

Laser based powder bed fusion of polymers (PBF-LB/P) is an additive manufacturing process that produces parts by selectively fusing a polymer powder bed using laser irradiation. PBF-LB/P conducted at a powder bed temperature below the crystallization temperature measured by DSC, referred to as the low-temperature process, offers advantages such as reduced thermal degradation of the material and an expanded range of compatible materials. However, the shrinkage behavior of low-temperature process significantly differs from that of conventional PBF-LB/P due to differences in the preheating temperature of the powder bed. Consequently, this hinders the direct application of conventional shape compensation strategies, and there is a need for a dedicated deformation prediction model. Laser based powder bed fusion of metal (PBF-LB/M) exhibits similar characteristics, that crystallization is initiated immediately after the heating beam has passed, and several commercial simulation tools are available to predict the deformation. Nevertheless, it remains unclear whether the approaches developed for PBF-LB/M can be directly applied to low-temperature polymer process, given the large differences in the material properties. This study investigated stress evolution and deformation induced by shrinkage during the build process in low-temperature process, with emphasis on identifying the similarities and differences relative to PBF-LB/M. The results showed that the residual stresses after low-temperature process were substantially lower than those in PBF-LB/M. In contrast, the strain and resulting deformation were more pronounced in low-temperature process. The findings indicated that deformation should be the primary focus in the development of prediction models for low-temperature process rather than the residual stress-centric prediction models typically used for PBF-LB/M.