Optimization of formability of silica matrix composite powder via particle size distribution model for selective fibre-laser sintering

Composite powders consisting of silica particles, thermosetting phenolic resin (TSPF) and graphite were developed for selective fibre-laser sintering (F-SLS). Two alternative particle packing/size distribution models, such as, Andreasen model and Horsfield theory were employed in this work. The result shows all composite powders exhibit good flowability. While the grey-scale value of the powder based on Horsfield theory was smaller than that based on Andreasen model, resulting in an improvement of the laser absorption rate. F-SLS material derived from composite powders graded according to the Horsfield model achieved lower porosity and higher strength than those derived from those according to the Andreasen model, the final tensile strength being 40% higher (1.26 MPa).