High Pressure Spray Process for Polymer Particles applicable for Laser Polymer Deposition (LPD)

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The aim of the project is the development and the basic understanding of two processes for the production and processing of polymer powders. The technologies developed in this project will allow to process new polymer materials, thus creating the basis for a broader base of raw materials in 3D additive manufacturing. With a high-pressure spray process polymer particles are produced with smooth surfaces, which cannot be produced with the established manufacturing processes or only very cost intensive. By changing the process parameters of the high-pressure process, particle sizes, particle morphologies and crystallinities of the polymer powders produced are deliberately changed and adjusted. The generated particle systems are processed in a newly developed laser polymer deposition (LPD) process, which is based on the established laser metal deposition (LMD). In contrast to the established selective laser sintering (SLS) technology, which uses CO2 laser, LPD technology relies on cost-effective and more energy efficient solid-state lasers. Therefore, the optical properties of the polymer particles will be optimized with regard to the absorption at the laser wavelength of around 1 µm by adding additives. The new processing technology in the field of polymer systems enables higher processing speeds and lower material usage. Process development and optimization for 3D additive manufacturing is based on systematic analysis of the micro- and macro-scale properties of the polymer components and powders produced. Differential calorimetric and X-ray diffractometric investigations will provide information about the crystallinity and the thermal processing ranges of the polymer powders. Tensile and bending tests show the processability of the polymer powders and help to optimize the laser process as well as the particle generation. With a thermoplastic polyurethane an elastomer will be developed for additive manufacturing.For the second project period of the priority program, a polylactic acid shall be used to test a biodegradable polymer and polypropylene as a thermoplastic mass product with the newly developed LPD process. In addition, the LPD process will be extended to the production of hybrid polymer/metal components.