Laser Sintering Research Articles

Additive Manufacturing Technology in the Furniture Industry: Future Outlook for Developing Countries

For the past few years, the adoption of 3D printing technology has benefited various manufacturing industries, including the furniture making industry. However, this adoption has been greatly seen in industrialized countries and lacking in developing countries. Therefore, to understand fully the capability of 3D printing and its benefits, this paper review discusses recent applications of 3D printing in the furniture industry and assesses the potential it can bring for developing countries’ furniture making industry, specifically in the Philippines and other developing countries in Asia. In addition, the drawbacks it brought to the industry, and the challenges that needed to be addressed are also discussed in the paper. The paper covers various 3D printing technologies such as material extrusion, sheet lamination, powder bed fusion, and vat photopolymerization, along with different materials currently used in the furniture industry. Numerous notable examples of applications of 3D-printed furniture are also presented. Based on the review paper, it was found that the most common 3D printing technologies used in the furniture industry are Material Extrusion (MEX) and Powder Bed Fusion (PBF) specifically Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS), respectively. The most common 3D printing materials used are Polyamide (PA), Polylactic acid (PLA), and recycled Polyethylene terephthalate glycol (PETG). The paper also discusses the possible adoption of 3D printing in developing countries and explores its potential to innovate traditional furniture manufacturing processes.

Laser powder bed fusion sintering mechanism of phenolic resin investigated by ReaxFF molecular dynamics simulations

ABSTRACT This study presents an innovative approach utilising molecular dynamics simulations to elucidate the polymerisation and neck formation mechanisms of phenolic resin during laser powder bed fusion (L-PBF). By developing system and dual-particle models and employing infrared thermal imaging, we established a heat source model for phenolic resin under varying parameters. Our molecular dynamics simulations, using the ReaxFF reactive force field, indicate that high-power lasers significantly enhance cross-linking, achieving a peak polymerisation degree of 78.9% at 30W and 35W power levels. Conversely, increased scanning speed slows product degradation, reducing the polymerisation degree. The interplay of laser power and scanning speed influences polymerisation, with total input energy and heating rate impacting polymerisation and molecular size. Additionally, we investigated neck formation, revealing that small vortices evolve into larger ones during sintering, promoting neck formation. Optical microscopy confirmed diverse neck shapes under different conditions. Quantitative data showed that at a scanning speed of 1000 mm/s, the polymerisation degree reached 93%, with only 2 molecules remaining post-simulation. At 30W power, the largest individual molecule observed was C849H703O117. This research offers crucial insights for selective laser sintering processes, emphasising the importance of high energy input and optimal heating rates for well-formed necks.

Nylon 12 composite powder prepared by thermally induced phase separation for selective laser sintering

Nylon 12 composite powder prepared by thermally induced phase separation for selective laser sintering

Investigating into casting LMPA (low-melting-point alloy) with 3D-printed mould and inspecting quality using 3D scanning

PurposeThree-dimensional (3D) casting means using additive manufacturing (AM) techniques to print the mould for casting the cast tool. The printed mould, however, should be checked for its dimensional accuracy. 3D scanning can be used for the same. The purpose of this study is to combine the different AM techniques for 3D casting with 3D scanning to produce parts with close tolerance for preparing electrical discharge machining (EDM) electrodes.Design/methodology/approachThe four processes, namely, stereolithography, selective laser sintering, fused deposition modelling and vacuum casting, are used to print the casting mould. The mould is designed in two halves, assembled to form a complete mould. The mould is 3D scanned in two stages: before and after using it as a casting mould. The mould's average and maximum dimensional deviations are calculated using 3D-scanned results. The eutectic Sn-Bi alloy is cast in the mould. The surface roughness of the mould and the cast tool are measured.FindingsThe cast tool is selected from the four processes in terms of dimensional accuracy and surface finish. The same is electroplated with copper. The microstructure of the cast tool (low-melting-point alloy) and deposited copper is analysed using a scanning electron microscope. Energy dispersive spectroscopy and X-ray diffraction techniques are used to verify the composition of the cast and coated alloy. The electroplated tool is finally tested on the EDM setup. The material removal rate and tool wear are measured. The performance is compared with a solid copper tool. The free-form customised EDM mould is also prepared, and the profile is cast out. The same is tested on the EDM. Thus, the developed path can be successfully used for rapid tooling applications.Originality/valueThe eutectic composition of Sn-Bi is cast in the 3D-printed mould using different AM techniques combined with 3D scanning quality to check its feasibility as an EDM electrode, which is a novel work and has not been done previously.

An experimental and theoretical investigation on the hyper-viscoelasticity of polyamide 12 produced by selective laser sintering.

Polyamide 12 (PA12) is vastly utilized in many additive manufacturing methods, such as Selective Laser Sintering (SLS), and a better understanding of its mechanical behaviors promotes available knowledge on the behaviors of 3D-printed parts made from this polymer. In this paper, SLS-produced standard tensile specimens are studied under monotonic and cyclic tension tests, as well as stress relaxation experiments, and the obtained force-displacement responses are shown to be consistent with a hyper-viscoelastic material model. This finding is also observed in typical pantographic structures produced by the same manufacturing parameters. To propose a constitutive model for predicting these behaviors, the convolution integral of a strain-dependent function and a time-dependent function is developed where the material parameters are determined with the use of both short-term and long-term responses of the specimens. Numerical results of the presented model for standard test specimens are shown to be in good agreements with the experimental ones under various loading conditions. To prove the capabilities of the proposed model in studying any SLS-produced part, finite element implementation of the constitutive equations is shown to provide numerical results in agreement with the empirical findings for tensile loading of the 3D-printed pantographic structure.

Study the potential of micro laser sintering additive manufacturing technology for metallic 3D printing horn antenna structure

AbstractApplications for an antenna structure produced with additive manufacturing technology are numerous and promising. This study focuses explicitly on utilizing micro‐laser sintering (MLS) three‐dimensional (3D) printing technology to fabricate two rectangular horn antennas identical to a standard Pasternack® horn antenna, making the fabrication straightforward. The objective is to investigate how surface roughness affects antenna performance in a frequency range of 18 to 26.5 GHz. One antenna is polished and the other is left untouched, resulting in surface roughness of 4 and 6 µm, respectively, measured using a profilometer. Then, a vector network analyzer was used to assess their reflection coefficient, transmission characteristics, and radiation pattern and determine gains of 8.83 and 9.14 dBi for the polished and unpolished antennas, respectively. The study finds that both polished and unpolished antennas perform similarly, and their characteristics closely resembling simulated and standard antennas. Finally, the performance of the MLS‐printed metallic antennas is compared with horn antennas created using other 3D printing techniques. It reveals that the MLS‐printed metallic structures exhibit better performance, indicating that the MLS technology has great potential to print 3D metallic electromagnetic designs.

Influence of various fabrication techniques and porcelain firing on the accuracy of metal-ceramic crowns

BackgroundThe fit of a metal-ceramic restoration is essential to its long-term durability. Regarding marginal and internal fit, there is not enough information about the technologies used in the production of metal-ceramic restorations. The aim of this in vitro study is to compare, both before and after porcelain firing, the marginal, axial, axio-occlusal, and occlusal fit of metal-ceramic restorations manufactured using casting, additive or subtractive computer-aided design, and computer-aided manufacturing techniques (CAD/CAM).MethodsCAD/CAM were used to create 50 prepared maxillary first molar-shaped Co-Cr die models, which were randomly divided into 5 groups (n = 10). Cobalt-chrome copings were produced by casting (C), hard metal milling (HM), soft metal milling (SM), selective laser melting (SLM), and selective laser sintering (SLS) techniques. Before and after porcelain firing, discrepancies of the copings were measured using the silicone replica technique. The data obtained by measurements with a stereomicroscope at x80 magnification were analyzed statistically in the SPSS program. The ROBUST three-way analysis of variance (ANOVA) method was used to compare the discrepancy values.ResultsThere were statistically significant differences among fabrication methods (P < .001). The HM method showed the highest discrepancy (90.1 μm), and the C (63 μm) method showed the lowest discrepancy in terms of the die model- crown fit. The C, SLS, and SM methods (63 μm; 61.6 μm; 67.7 μm) were statistically similar (P > .001). The highest discrepancy was observed on the occlusal area (87.1 μm), and the lowest discrepancy was observed on the axial area (47.7 μm) of the coping. Porcelain firing had a decrease in the discrepancy values (P = .001).ConclusionAll CAD/CAM techniques are appropriate for clinical use; selective laser sintering and soft milling can be the more recommended methods for the compatibility of metal-porcelain restorations, as they have lower discrepancy values than the SLM and HM methods.

Study on the wear characteristics of a 3D printed tool in flat lapping of Al2O3 ceramic materials

Widespread and popular use of ceramic products in various industry sectors necessitates the search for methods of their efficient processing. Lapping technology, which enables obtaining high dimensional and shape accuracy and high surface flatness, is one of the basic methods of finishing hard and brittle technical ceramics with a porous structure. This study analyzed the characteristics and wear value of an SLS-printed abrasive tool intended for single-sided lapping of Al2O3 technical ceramics. As earlier research demonstrated, introduction of a 3D printed lapping plate by selective laser sintering (SLS), leads to a significant development in the field of precision machining technology. This method showed not only efficient machining performance on oxide technical materials, but was also characterized by relatively low abrasive wear. Straightness errors were evaluated with the use of a least-squares method (LSQ) and minimum zone method based on control line rotation scheme (CLRS). The proposed model proved the experimental results by identifying a similar location of a higher contact density on the lapping tool, where this location is expected to be the one for bigger wear. Surface topography of the lapping tool depends on the tool wear intensity and as a consequence on its shape error. An SLS-printed lapping plate, by obtaining good technological effects, revealed its potential ability in machining hard and brittle technical ceramics.

Design optimization of cubic-shaped pressurant tank for CubeSat propulsion system

From a technical and economic point of view, cold gas propulsion for nanosatellites is one of the more rational systems. There is a problem, however: the optimal spherical shape for a high-pressure vessel only takes up half the cubic volume of the CubeSat unit. To increase the volume, it is proposed to switch to a cubic-shaped tank. The aim of this work is to synthesize the more rational structural design of a pressurant tank that fits within a cubic constraint, which provides the perfect balance between the mass of the structure and the delta-V budget available for the propulsion system. The proposed variants are as follows: a set of four cylinders with spherical bottoms; 14 equal spheres arranged in a face-centered cubic packing; a thin-walled cube supported by ribs, the location and parameters of which provide the smallest mass of the structure; a cube, the reinforcement scheme of which is calculated using topology optimization method; an original polyspheric and bypass design schemes where the filling of the volume of the cube is created by a set of spherical and cylindrical shells of different radii. All the considered vessel variants can be obtained using additive technologies, such as selective laser sintering. For each variant, the internal volume and mass of the vessels were obtained, as well as the delta-V budget, taking into account the mass of the tank and the mass of the stored gas. The analysis of the results reveals that there are two structures that are more rational. The new bypass scheme provides the largest delta-V budget, but it has a 1.6 times larger mass than the initial spherical vessel design. It should be noted that the difference in vessel mass is not crucial for CubeSat form factor satellites. Choosing a rational design may require a larger delta-V budget. The possibility of increasing the reserve delta-V of the CubeSat cold gas propulsion system by 25–35 % due to the transition from a spherical to a cube-shaped tank has been demonstrated. At the same time, the mass of the tank structure increases by 1.6–6.3 times, which can be considered an acceptable price for increasing the efficiency of the propulsion system. The new bypass scheme offers the optimal balance of mass and delta-V reserve.

3D printing of sustainable wood-based bio-composites for high-end custom carton

This research delves into an upscale, personalised packaging paradigm employing 3D printing and a bio-composite derived from esteemed rosewood. The study incorporates a design for additive manufacturing, enhancing designers’ flexibility, and fostering innovation. To address global sustainability imperatives, including efficiency, energy conservation, a low carbon footprint and ecological compatibility, a premium and sustainable rosewood/polyethersulfone (PES) composite is developed. Laser sintering (LS), renowned for its processing flexibility, is applied for crafting intricate packages. A weight ratio of 1:4 of rosewood to PES is highly suitable for LS processing. The resultant custom carton, embodying natural rosewood aesthetics and fragrance, exhibits commendable mechanical robustness and precision. Tensile and bending strengths reach peaks of 4.880 MPa and 7.870 MPa, respectively, under a 9-W laser power. Scanning electron microscope (SEM) analysis confirms the favourable dispersion of rosewood fibres in LS specimens, providing insights into the microstructure of the composite powder.

Selective laser sintering and spark plasma sintering of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide ceramics

AbstractTwo advanced manufacturing processes, spark plasma sintering (SPS) and selective laser sintering (SLS), have been developed for synthesis of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide (CCC) via reactive sintering of a powder mixture of constitute monocarbides. X‐ray diffraction analysis confirmed that the single‐phase CCC can be formed by both SPS and SLS. While a homogenous microstructure with uniform metal element distributions was developed during SPS, three‐layer microstructures with a thin TiC‐rich layer and two TaC‐rich layers along with a TiO2‐rich surface layer containing W nanoparticles were formed during SLS. In addition, cellular structures with W, Zr, and Ti element segregation and dislocations on cell boundaries were observed in the SLS‐CCC sample, indicating the effect of nonequilibrium conditions on microstructure formation during laser melting followed by rapid cooling and solidification process. Compared to the SPS‐CCC sample, the SLS‐CCC showed enhanced hardness and reduced thermal conductivity, which may be related to their unique cellular structures.

Experimental analysis of failure behaviour of PA12 specimens manufactured by SLS as a function of wall thickness and build direction

PurposeThis paper aims to investigate and explain the dual fracture behaviour of PA12 specimens sintered by selective laser sintering (SLS) as a function of wall thickness and build direction with a powder mixture 30:70. To achieve this objective, research related to chemical, thermal and structural behaviours as a function of the input variables was carried out to describe and explain why ductile-fragile behaviour occurs during fractures under uniaxial tension manufactured via a methodology of material analysis and manufacturing processes.Design/methodology/approachThe factorial design 32 relates the fracture of PA12 tensile specimens to the horizontal, transverse and vertical build directions at 2.0, 2.5 and 3.0 mm thicknesses, respectively. Fractographic images revealed the fracture surfaces and their dual ductile-fragile behaviour related to the specimens’ measured crystalline, thermal, surface and chemical properties.FindingsThe study showed that thermal property variables differ depending on the input variables. The wall thickness variable affected this morphology the most, showing the highest percentage of the ductile area, followed by the transverse and vertical directions. It was determined that the failure in the vertical direction is due to crystalline gradients associated with the layer-by-layer construction process. The pore density may be closely related to generating ductile and brittle areas.Originality/valueIn this paper, fracture characterisation is performed based on the mechanical, chemical, structural, thermal and morphological properties of PA12 manufactured by SLS. In addition, a heatmap of porosities in cross-sections is constructed using a machine learning model (k-means) related to dual fracture behaviour. This research revealed significant differences in the fracture type according to the build direction. In addition, thin-section fractography provides a more detailed explanation of the fragile behaviour of the vertical direction associated with crystalline changes due to the direction of the sintering layers.

Effect of Pore Architecture of 3D Printed Open Porosity Cellular Structures on Their Resistance to Mechanical Loading: Part I – Experimental Studies

Abstract The development of additive manufacturing (AM) techniques has sparked interest in porous structures that can be customized in terms of size, shape, and arrangement of pores. Porous lattice structure (LS, called also lattice struct) offer superior specific stiffness and strength, making them ideal components for lightweight products with energy absorption and heat transfer capabilities. They find applications in industries such as aerospace, aeronautics, automotive, and bone ingrowth applications. One of the main advantages of additive manufacturing is the freedom of design, control over geometry and architecture, cost and time savings, waste reduction, and product customization. However, the designation of appropriate struct/pore geometry to achieve the desired properties and structure remains a challenge. In this part of the study, five lattice structs with various pore sizes, with two volume fractions for each, and shapes (ellipsoidal, helical, X-shape, trapezoidal, and triangular) were designed and manufactured using selective laser sintering (SLS) additive manufacturing technology. Mechanical properties were tested through uniaxial compression, and the apparent stress-strain curves were analyzed. The results showed that the compression tests revealed both monotonic and non-monotonic stress-strain curves, indicating different compression behaviors among the structures. The helical structure exhibited the highest resistance to compression, while other structures showed similarities in their mechanical properties. In Part II of this study provides a comprehensive analysis of these findings, emphasizing the potential of purpose-designed porous structures for various engineering applications.

Cold Laser Sintering of Medicines: Toward Carbon Neutral Pharmaceutical Printing.

Selective laser sintering (SLS) is an emerging three-dimensional (3D) printing technology that uses a laser to fuse powder particles together, which allows the fabrication of personalized solid dosage forms. It possesses great potential for commercial use. However, a major drawback of SLS is the need to heat the powder bed while printing; this leads to high energy consumption (and hence a large carbon footprint), which may hinder its translation to industry. In this study, the concept of cold laser sintering (CLS) is introduced. In CLS, the aim is to sinter particles without heating the powder bed, where the energy from the laser, alone, is sufficient to fuse adjacent particles. The study demonstrated that a laser power above 1.8 W was sufficient to sinter both KollicoatIR and Eudragit L100-55-based formulations at room temperature. The cold sintering printing process was found to reduce carbon emissions by 99% compared to a commercial SLS printer. The CLS printed formulations possessed characteristics comparable to those made with conventional SLS printing, including a porous microstructure, fast disintegration time, and molecular dispersion of the drug. It was also possible to achieve higher drug loadings than was possible with conventional SLS printing. Increasing the laser power from 1.8 to 3.0 W increased the flexural strength of the printed formulations from 0.6 to 1.6 MPa, concomitantly increasing the disintegration time from 5 to over 300 s. CLS appears to offer a new route to laser-sintered pharmaceuticals that minimizes impact on the environment and is fit for purpose in Industry 5.0.

Flow Through a Passage With Scaled Additive Manufacturing Roughness Representing Different Printing Orientations

Abstract Components with internal passages created using some laser-sintering based, additive manufacturing (AM) systems can exhibit anisotropic surface features with an appearance of three-dimensional roughness superimposed on two-dimensional, rib-like features. This paper presents an investigation of flow over roughness representing internal cooling passages printed at different angles to the AM printing plane. A roughness geometry was acquired using an X-ray tomography scan of a direct-metal-laser-sintering (DMLS) created coupon with internal cooling passages. The base surface scan was then used to create four surfaces with notional rib-like features positioned at different angles relative to the spanwise flow direction. The flow resistance of each surface was measured using the roughness internal flow tunnel. The mean flow velocity profiles for the cases with ReDh ≤ 30,000 were characterized using a four-camera, tomographic, and particle tracking system. The results demonstrate roughness orientation effects include (1) reduced bulk flow resistance as the alignment angle from the spanwise direction increases, (2) generated flow in the spanwise direction and increased tunnel flow swirl as the alignment angle increases, and (3) velocity profile changes as the flow migrates away from the rough side of the tunnel to the opposing smooth wall. The particle tracking system also demonstrates that the mean streamwise flow profiles change significantly between the 30 deg and 45 deg roughness orientations. Finally, the equivalent sandgrain roughness measurements for the four surfaces were found to follow the trends predicted using the correlations of Bons (2002, “St and cf Augmentation for Real Turbine Roughness With Elevated Freestream Turbulence,” ASME J. Turbomach., 124(4), pp. 632–644.) and Sigal and Danberg (1990, “New Correlation of Roughness Density Effect on the Turbulent Boundary Layer,” AIAA J., 28(3), pp. 554–556.).

Advancements in diabetic foot insoles: a comprehensive review of design, manufacturing, and performance evaluation.

The escalating prevalence of diabetes has accentuated the significance of addressing the associated diabetic foot problem as a major public health concern. Effectively offloading plantar pressure stands out as a crucial factor in preventing diabetic foot complications. This review comprehensively examines the design, manufacturing, and evaluation strategies employed in the development of diabetic foot insoles. Furthermore, it offers innovative insights and guidance for enhancing their performance and facilitating clinical applications. Insoles designed with total contact customization, utilizing softer and highly absorbent materials, as well as incorporating elliptical porous structures or triply periodic minimal surface structures, prove to be more adept at preventing diabetic foot complications. Fused Deposition Modeling is commonly employed for manufacturing; however, due to limitations in printing complex structures, Selective Laser Sintering is recommended for intricate insole designs. Preceding clinical implementation, in silico and in vitro testing methodologies play a crucial role in thoroughly evaluating the pressure-offloading efficacy of these insoles. Future research directions include advancing inverse design through machine learning, exploring topology optimization for lightweight solutions, integrating flexible sensor configurations, and innovating new skin-like materials tailored for diabetic foot insoles. These endeavors aim to further propel the development and effectiveness of diabetic foot management strategies. Future research avenues should explore inverse design methodologies based on machine learning, topology optimization for lightweight structures, the integration of flexible sensors, and the development of novel skin-like materials specifically tailored for diabetic foot insoles. Advancements in these areas hold promise for further enhancing the effectiveness and applicability of diabetic foot prevention measures.

Effect of shape and thermal conductivity of microstructured capillary-porous coatings on heat transfer during evaporation and boiling in thin horizontal liquid layers

Investigation results on heat transfer during evaporation and boiling in thin horizontal liquid layers on 2D modulated capillary-porous coatings with a sinusoidal profile in a wide range of relative pressures and layer heights are presented in this paper. Coatings were made on a 3D laser printer using the technology of additive selective laser sintering (SLS). One coating was made of bronze with a modulation wavelength equal to the Laplace constant of the working fluid and two coatings were made of stainless steel and bronze with a doubled wavelength. The experimental data obtained on the coatings were compared with each other and with the values obtained by evaporation and boiling of n-dodecane on a smooth surface under the same conditions. It is shown that in the region of low relative pressures in liquid layers with a height less than the Laplace constant, heat transfer intensification achieved on a sample made of a material with low thermal conductivity (stainless steel) was five times higher as compared to a smooth surface. In the range of relative pressures, when nucleate boiling was observed in the layers, the temperature difference reached on the bronze coatings was approximately 3–4 times less than on a smooth surface. The temperature difference for the stainless steel coating changed little with an increase in the heat flux. In pre-crisis conditions, the temperature difference during boiling on the stainless steel coating was less than on the bronze coatings in the entire range of relative pressures and layer heights. The highest critical heat fluxes were obtained on a bronze coating with a modulation wavelength equal to the Laplace constant.

Friction and wear performance of 3D-printed graphite/SiC composites with different graphite layer deflection angles

This study explores the combination of selective laser sintering 3D printing of graphite with the melt infiltration of silicon to produce graphite/SiC self-lubricating composites featuring graphite layers with varying deflection angles. The findings suggest that the deflection angle of graphite layers plays a crucial role in influencing the friction and wear characteristics of the composite materials. Specifically, graphite layers with deflection angles below 45° result in surface crushing and the stacking of lubricating films, leading to a noticeable ploughing effect. Conversely, deflection angles exceeding 60° cause, the graphite layers to break easily within the substrate, making it challenging to consistently provide lubrication over an extended period, consequently resulting in severe abrasive wear. In the range of 45° to 60° deflection angles, the graphite layers exhibit a tendency towards sliding dispersion, facilitating the dynamic filling of surface pits and scratches. This behavior contributes to the demonstration of low friction coefficients (ranging from 0.11 to 0.14) and exceptional wear resistance (measured at 3.23 to 3.79 ×10−6 mm3/Nm).

3D Printable Antimicrobial Polymer Blend

AbstractThree‐dimensional (3D) printing is an innovative manufacturing method for preparing designer materials with complex geometries. However, there are very few studies on the fabrication of antimicrobial polymer materials suitable for use in everyday clinical objects, via 3D printing. In this work, an antibacterial polymer material is prepared by blending polyamide 11 (matrix), a high‐performance engineering thermoplastic, and a styrene maleimide copolymer with pendant quaternary amine moieties, and the blend 3D printed via selective laser sintering. The quaternary amine functionalities confer permanent antimicrobial properties. Blend properties are studied prior to printing via differential scanning calorimetry, powder X‐ray diffraction, and FTIR spectroscopy. Additionally, the mechanical and antimicrobial properties of the polymer blends and printed material are also assessed. The microstructure of the 3D printed polymer materials is further characterized via DOSY NMR spectroscopy. This study indicates that this is a promising approach for preparing nonleaching antimicrobial 3D printable materials.

Carbon nanotubes/α-ZrP sheets for high mechanical performance and flame-retarding polyamides using selective laser sintering

ABSTRACT The current study presents a facile approach to synthesis carbon nanotube-anchor α-ZrP (CNT@α-ZrP) nanohybrid for multifunctional polyamide 12 (PA12) composites via ball-milling followed by selective laser sintering (SLS) process. Herein, CNTs serve dual roles; firstly, they act as a pigment, imparting black colouration to both PA12 powder and α-ZrP sheets, facilitating rapid light absorption and heating. Secondly, CNTs complement α-ZrP sheets to reinforce the PA12 matrix for strong and functional structures. The dominant filler content is α-ZrP nanosheets in PA12 powder to study the functionality of α-ZrP sheets in SLS-PA12 composites. CNT@α-ZrP hybrid enhances mechanical, tribological, corrosion resistance and flame-retarding properties of PA12 composite parts. PA12/CNT@α-ZrP composite exhibited 98.9%, 33.1%, and 34.6% increments in Young's modulus, tensile strength and impact strength, respectively. To predict the response of the composites across a range of applications, the constants for different hyperelastic models describing their mechanical behaviour were determined. The coefficient of friction and wear rate of the sintered composite parts were reduced significantly. Additionally, 1 wt% CNT@α-ZrP reduced smoke production rate and total smoke production by 36.5% and 13.8%, respectively along with a 2.2- fold increment in time-to-ignition. The work presents an industrial method to develop strong and functional intricate structures via SLS.