Multi-Process Printing Method Combining Powder and Resin Based Additive Manufacturing

Abstract

• Novel process for printing components consisting of SLS powders and SLA resins. • This novel process allows you to combine the strength of SLS parts with the surface finish of SLA components. • Could be used to print conductive metal channels into a non-conductive resin part. We propose a novel additive manufacturing (AM) method that combines both powder-based and resin-based printing processes. Both resin-based and powder-based processes have unique advantages ranging from strength and variety of materials for powder processes, to resolution and surface finish for resin printing. Previously, we proposed a novel powder-based printing process that directs a laser beam upwards to fuse powders through glass to a substrate. However, this setup can also be used to solidify resin as a secondary material in the same print. We demonstrate this hybrid process by fabricating samples containing both resins and powders. We also examine the potential for resin to be used to reduce powder bed fusion part porosity as well as adjust part surface finish. We discuss the impacts of these results and propose future uses.