Selective laser sintering (SLS)-printable thermosetting resins via controlled conversion

An alternative strategy toward SLS-printable thermosets is demonstrated based on partial curing of the material to increase the T-g of the resin and minimize the additional cure needed to cross-link the printed article. This material is then printed, yet it does not become cross-linked during the printing process. Rather, after printing the material is cured via a slow temperature ramp maintained just below the material's evolving T-g. Although equipment limitations resulted in parts which have intrinsic porosity, the strategy employed here serves as the first demonstration of SLS printing and subsequent curing of minimally filled (< 1 wt% filler) high T-g (similar to 200 degrees C) thermoset materials competitive with popular thermoplastics such as PEEK and PPS.