Disentangled UHMWPE composites for warp-free SLS parts

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The proposed project targets the preparation and use of tailor-made polymer composite particles in SLS, allowing to generate SLS parts with extended properties, in particular with the aim to overcome the current limited interlayer adhesion. The combination of in-situ polymerization techniques for the production of functional powders and simulation supported process optimization for generating SLS parts is the approach to reach improved mechanical and dimensional stability of the resulting parts. In a first approach, single-walled CNT nanocomposites powders with disentangled UHMWPE will be prepared and sintered. This would lead to parts based on UHMWPE; latter was chosen as material for the parts on account of the outstanding mechanical and chemical stability. It is expected that the formation of entanglement in the sintering process will lead to a much higher adhesion between the particles, also given by the lower viscosity of the starting composite.A numerical simulation will be established validated and adapted by data recorded from a thermal camera. Then the temperature distribution assessed by the simulation will be correlated to the material-specific crystallization behavior. Based on this correlation inhomogeneous crystallization and thus warpage will be avoided by means of post-build temperature adjustments.Subsequently, the material properties of SLS parts will be determined, compared against reference materials like commonly molded UHMWPE nanocomposites. A feedback and optimization loop will be thus established regarding material properties and process parameter.