Innovative Selective Laser Sintering Rapid Manufacturing using Nanotechnology

The objective of this research is to develop an improved nylon 11 (polyamide 11) polymer with enhanced flame retardancy, thermal, and mechanical properties for selective laser sintering (SLS) rapid manufacturing (RM). A nanophase was introduced into nylon 11 via twin screw extrusion to provide improved material properties of the polymer blends. Atofina (now known as Arkema) RILSAN® nylon 11 injection molding polymer pellets was used with three types of nanoparticles: chemically modified montmorillonite (MMT) organoclays, nanosilica, and carbon nanofibers (CNF) to create nylon 11 nanocomposites. Wide angle X-ray diffraction (WAXD) and transmission electron microscopy (TEM) were used to determine the degree of dispersion. Fifteen nylon 11 nanocomposites and control nylon 11 were fabricated by injection molding. Flammability properties (using a cone calorimeter with a radiant flux of 50 kW/m2 ) and mechanical properties such as tensile strength and modulus, flexural modulus, elongation at break were determined for the nylon 11 nanocomposites and compared with the baseline nylon 11. Based on flammability and mechanical material performance, five polymers including four nylon 11 nanocomposites and a control nylon 11 were cryogenically ground into fine powders for SLS RM. SLS specimens were fabricated for flammability, mechanical, and thermal properties characterization. Nylon 11-CNF nanocomposites exhibited the best overall properties for this study.Mechanical Engineerin