Functional prototypes produced via laser sintering already address the sub millimeter region with resolutions in the low
micrometer range. The manufacturing process is very suitable for small scale, micro featured functional polymer parts
because of its ability to generate complex and fine shaped geometries including undercuts and pores. The parts are built
up layer by layer from three-dimensional data generated by CAD programs or by micro computer tomography as a copy
of already existing parts. Up to now this field is dominated by polyamide, a semi-crystalline polymer. This thermoplastic
material covers a wide range of applications but requirements concerning a high temperature resistance above 200 °C
and tensile strengths above 50 N/mm2 are not fulfilled despite glass fillings. A change in the sintering material can solve
this issue. Investigations show that polyetheretherketone (PEEK) which is a high performance polymer with a melting
temperature of 346°C can be used for laser sintering. Manufacturing small sized and micro featured parts with enhanced
temperature and mechanical properties is possible using an adapted system technology.
For minimum vertical outer features a value of about 250 &mgr;m was found, expanded outer features like walls show a
width of 650 &mgr;m. A first low boundary for hole-diameters in the feeding 3D-data set was found. As a basic boundary for
minimum geometrical features a core roughness average of about 23.3 &mgr;m could be measured.
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