Selective laser sintering (SLS)-printable thermosetting resins via controlled conversion

An alternative strategy toward SLS-printable thermosets is demonstrated based on partial curing of the material to increase the Tg of the resin and minimize the additional cure needed to cross-link the printed article. This material is then printed, yet it does not become cross-linked during the printing process. Rather, after printing the material is cured via a slow temperature ramp maintained just below the material’s evolving Tg. Although equipment limitations resulted in parts which have intrinsic porosity, the strategy employed here serves as the first demonstration of SLS printing and subsequent curing of minimally filled (< 1 wt% filler) high Tg (~ 200°C) thermoset materials competitive with popular thermoplastics such as PEEK and PPS.