Functionally graded Nylon-11/silica nanocomposites produced by selective laser sintering

Selective laser sintering (SLS), a layered manufacturing-based freeform fabrication approach was explored for constructing three-dimensional structures in functionally graded polymer nanocomposites. Here, we report on the processing and properties of functionally graded polymer nanocomposites of Nylon-11 filled with 0–10% by volume of 15 nm fumed silica nanoparticles. SLS processing parameters for the different compositions were developed by design of experiments (DOE). The densities and micro/nanostructures of the nanocomposites were examined by optical microscopy and transmission electron microscopy (TEM). The tensile and compressive properties for each composition were then tested. These properties exhibit a nonlinear variation as a function of filler volume fraction. Finally, two component designs exhibiting a one-dimensional polymer nanocomposite material gradient were fabricated. The results indicate that particulate-filled functionally graded polymer nanocomposites exhibiting a one-dimensional composition gradient can be successfully processed by SLS to produce three-dimensional components with spatially varying mechanical properties.