High speed sintering: The influence of print density on feature resolution and accuracy

Abstract

High Speed Sintering is a novel additive manufacturing technology which uses an InkJet printhead and infra-red radiation. The printhead deposits a radiation absorbing material directly onto a powder bed, the entire bed is then irradiated by an infrared lamp. Areas printed with radiation absorbing material will absorb sufficient energy to sinter, whereas areas without will not. Another layer of powder is deposited and the process repeats until the part is complete. To date, a large proportion of research has used the maximum print density possible, very little research has focused on how altering print density influences the minimum feature size and dimensional accuracy. As such this research was designed to investigate how print density influences feature resolution, accuracy and powder removability. Results showed improved powder removal and feature resolution can be achieved using a print that is not fully dense. However, beyond a certain point the print density becomes too low and the parts fail. Thus it is imperative that the correct balance is struck if parts are to be manufactured successfully and possess improved accuracy and feature resolution.