Selective laser sintering (SLS) of Nylon is a significant portion of the additive manufacturing market for structurally sensitive applications. Current methods of acceptance for such parts are based on the inclusion of ASTM tensile test specimens within the build volume to assess the overall build quality. Ultimate strength and elongation of these specimens oriented both in-plane and normal to the layer build direction are the primary quality metrics. This paper looks at a more complete method of certifying parts for acceptance based on examination of the build conditions in each layer of the part by comparing layer-by-layer thermal conditions during the part build to the resulting ASTM specimen tensile properties. Through such a comparison, a more complete three-dimensional assessment of part quality during the build process can be constructed. The layer-by-layer assessment used here is derived from infrared thermal imaging; mapping temperature profiles of SLS-built tensile bars with data collected before, during, and after each layer-wise laser melting sequence. Mechanical properties and fracture conditions are then quantified and correlated with the conditions where the fractures occur. Build conditions associated with poor failure conditions may then be used to assess poor SLS bonding throughout the part volume, improving overall part quality assessment and certification. As the method is matured, real time layer-by-layer assessment will be linked to SLS control, to correct for observed defects during the build and improve overall part quality and repeatability.
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