Construction and Compensation of a Dimensional Accuracy Model of a Powder Bed via Laser Sintering

In the laser sintering (LS) printing process, a printed part is formed by sintering layer-by-layer on the powder bed. Thus, it is necessary to consider the dimensional accuracy of the laser-sintered powder bed as an important evaluation index. In this paper, a generalized powder bed–size accuracy compensation model is proposed for non-crystalline thermoplastic polymer materials. Taking polyethersulfone (PES) material as an example, the main factors influencing powder bed dimensional accuracy during LS printing are modeled and analyzed experimentally in this study, including four important factors: laser reference deviation, temperature deviation, density deviation, and secondary sintering deviation. In this study, CX_A200 LS equipment is used for prototyping and verification, a 3D scanning method is used to measure the printed parts, and the measurement results are digitally compared and analyzed. On this basis, the relationship of each influencing factor in the proposed compensation model is determined experimentally, and the experimental results demonstrate that the proposed compensation model is approximately 95% effective in terms of correcting the deviation of powder bed dimensional accuracy.