In this paper the processing parameters for 3D printing of HDPE via SLS technology is explored. Five different print types are developed by varying the output power of laser, chamber temperature, and scanning speeds between 10 mm/s and 80 mm/s in order to determine the optimal printing parameters that are needed for the manufacturing of consistent porous HDPE parts. The porosity of each print type is investigated via scanning electron microscopy (SEM). Experimental results demonstrates that Print Types I – IV have significant melted regions on the top layers of the print likely due to the absorption of heat overtime. Therefore, Print Type V is developed to eliminate curling by progressively increasing the scanning speed at increments of 1 mm/s between each layer, which can result in the desired HDPE prints with consistent porosity and drastically increased printability of complex geometries. Print Type V printing parameters are used to produce various HDPE prints with high quality and complex geometries.

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