Title: Optimised development of a prototype selective laser sintering powder recoating system via analytic hierarchy process

Authors: Panagiotis Avrampos

Addresses: Department of Manufacturing Technology, School of Mechanical Engineering, National Technical University of Athens, 9 Iroon Polytechneiou str., 15773, Zografou, Athens

Abstract: This article presents the methodological design and manufacturing of a prototype powder recoating system (PRS) for a custom selective laser sintering (SLS) machine aimed at investigating/modelling and benchmarking the process as regards polymer powders. Firstly, available powder deposition methods are examined, namely: mechanical, electrostatic, vibrational, aerosol-assisted spray and tower nozzle deposition. The analytic hierarchy process (AHP) is used to systematically compare and rank them according to criteria like: calibration need, spreading speed, deposited surface quality, functional simplicity, control/automation ease, manufacturing ease and cost. Mechanical method is found to be the most advantageous. Then, a custom PRS utilising a roller/blade combination is developed by providing engineering solutions for the individual functions that should be supported and divided into doser/siever and recoater groups. Each group is compared via AHP to the - widely adopted in industry - benchmark mechanical PRS and superiority of the prototype is proven. The latter's detail design is subsequently presented.

Keywords: selective laser sintering; SLS; selective laser melting; SLM; powder deposition; analytic hierarchy process; AHP; recoater; doctor blade; roller.

DOI: 10.1504/IJEDPO.2024.140451

International Journal of Experimental Design and Process Optimisation, 2024 Vol.7 No.2, pp.77 - 104

Received: 30 May 2023
Accepted: 25 Aug 2023
Published online: 19 Aug 2024 *

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