3D Printing Development
Selective Laser Sintering (SLS) - Materials Development
Technical Data Sheet Development
Managed sample preparation and coordination of testing for Nylon 11 & Nylon 12 technical data sheets.
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Nylon 12 was made available as a printable material when Fuse 1 launched in 2020, and Nylon 11 followed in May 2021. Educating customers on the physical and mechanical properties of parts printed with powder requires a technical data sheet (TDS). A market study of competitor’s powders yielded a list of commonly listed mechanical and biocompatibility properties. Appropriate test standards for these properties were researched, and samples prepared (designed in CAD, printed, and post-processed) in accordance with the appropriate ISO or ASTM standards. In-house testing was performed, and additional testing coordinated with external labs with ISO & ASTM certifications.
Powder Re-usability / Recyclability
​Quantified limits of powder recyclability and appropriate ‘refresh rates’ for customer use to reduce user waste and environmental contamination while maintaining print quality and advertised material properties for multiple materials.
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SLS printing inherently creates some waste powder in the printing process that can be recovered, and reused in printing. Many SLS printer manufacturers and powder distributors provide a recommended percentage of this used powder that can be mixed with fresh new powder to maintain mechanical properties and mitigate print artifacts while reusing as much of the waste as possible. Controlled sets of prints with a variety of refresh rate percentages were designed, tested, and evaluated to ensure consistent part quality while reducing customer waste. The appropriate refresh rate also varies depending on the material, so this testing is necessary for every new material release.
New Materials for Selective Laser Sintering
Explored additional printable materials for use with the Fuse 1 (eg Nylon 11).
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Nylon 12 launched with the Fuse 1, but the printer is not limited to just the one material. Potential material candidates were evaluated against known success criteria, and given go/no-go recommendations.