Experimental investigations of curling phenomenon in selective laser sintering process

Purpose - This paper aims to investigate the curling behaviour of selective laser sintered polyamide/glass bead composites with changes in material compositions, part bed temperature, powder base thickness, laser power and layer cooling time. Design/methodology/approach - The Taguchi parameter design method (design of experiments, DOE) and analysis of variance (ANOVA) technique were applied in the investigation to determine the optimal process parameter settings. Findings - The results of statistical analysis and ANOVA provided evidence for the effectiveness of filler content and its surface treatment on reducing the amount of curling. Research limitations/implications - Warping and curling phenomena is one of several aspects of this work that can be pursued further. The present investigation could be expanded to explore other fillers and interface adhesion using other modifiers. Experiments could be conducted with other complicated geometries, various sizes, different positions and locations to widen the knowledge base of geometric accuracy of selective laser sintering process. Practical implications - This experimental work is beneficial for materials development and accuracy characterisation in rapid manufacturing techniques. The experimental techniques adopted are readily transferable to virtually any material system used in rapid manufacturing. Originality/value - Although many materials have been developed, there is still a need for research into new materials. This work demonstrates that it is possible to improve the geometric accuracy of selective laser sintered components from glass bead-filled polyamide 12 and achieve near-zero curling by adding rigid multiphase-coated particle to the material system.