Fabrication of parts and their evaluation using a dual laser in the solid freeform fabrication system

A solid freeform fabrication (SFF) system using selective laser sintering (SLS) is currently recognized as a leading process for SLS extended application to machinery and automobiles, whose production involves the use of various materials. For the fabrication of a large surface using the SFF system, the dual-laser approach has been introduced in this paper. Since the building room is divided into two regions, each scan path for the dual-laser system is generated based on a single-laser scan path. The scan paths for both lasers have to be synchronized, and the mechanical strength of the large surface must be considered to prevent fracture at the interface region. This paper addresses the generation of a single-laser scan path for special cases such as those involving unnecessary scan points, and the generation of a dual-laser scan path according to various divided regions so to enhance the mechanical strength of the large surface. Moreover, the tensile strength of the specimen manufactured through single-laser scan path system has been compared with the specimen manufacture through dual-laser scan path and the effect of overlapping region with respect to tensile strength is also highlighted. (C) 2009 Elsevier B.V. All rights reserved.