The objective of this SBIR Phase I proposal is to perform experiments, guided by theory, to define and quantify the performance envelope of a new selective laser sintering process. In this process, a powder surface is raster-scanned with a high-power laser beam to fuse powder in areas to be occupied by the part at that particular cross-section. In areas not sintered, the powder remains loose and may be removed once the part is complete. Successive layers of powder are then deposited and raster-scanned until the entire part is produced. A general three-dimensional object can be produced in this way directly from a solid model or other three-dimensional computer database. The research effort will be directed toward investigation of process mechanics, material evaluation, effects of additives, and assessment of achievable strengths, dimensional tolerances, and part production rates. If successful, a follow-on Phase II is planned.
