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ALEX DEN OUDEN |
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Oude techniek en werktuigbouw, industriële geschiedenis en archeologie |
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The selective laser sintering process is a free-form fabrication method to create components by precise thermal fusing (sintering) of powdered materials. Parts of complex geometries are built in successive layers, that define subsequent cross sections of the component.
The sinter powder is power-fed to the process chamber from two cartridges flanking the partly built product. This allows for bi-directional powder feeding to the roller that lays powder across the top of the product, thus improving building speed. Unsintered powder is returned to the powder feeding cartridges, to be recycled. The laser is a CO2-type of 50 W power. The process chamber is filled with nitrogen to obtain safe material sintering conditions.
Materials most often used in selective laser sintering are polycarbonate and nylon. For polycarbonates, densities of 75-92% of that of the standard injection-moulded material can be obtained; for nylon even better values, 87-93%, have been realised. Another material that is well suited for the process is investment casting wax. This allows the direct construction of wax patterns for foundry use.
Considering the density results just mentioned, selective laser sintering is particularly suited to build fully functional prototypes in polycarbonates and/or nylons, that closely approximate the mechanical properties found in the final (i.e., injection-moulded) products. Such models can be tested before any capital outlay for the construction of injection moulds becomes necessary.
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