Optimizing processing parameters for selective laser sintering of peanut shell powder/polyether sulfone composite

Purpose This study aims to develop a novel wood-plastic composite using selective laser sintering (SLS) technology by combining peanut shell powder (PSP) and polyethersulfone (PES) (PSPC) to expand material options for SLS applications. Design/methodology/approach Initially, thermophysical tests were conducted on PSP and PES powders to evaluate the thermal behavior of PSPC, ensuring deformation is minimized during the sintering process. An orthogonal experimental design was used to optimize SLS parameters, i.e. scan spacing, laser power, layer thickness, preheating temperature and scanning speed. The optimization focused on improving mechanical properties, i.e. impact, tensile and bending strengths, as well as density and precision. Scanning electron microscopy was used to analyze the microstructure, particle distribution and formability of PSPC samples across different mixture ratios and SLS settings. Findings Based on orthogonal test data analysis, the properties of PSPC parts were found to be directly influenced by key SLS parameters. The optimized SLS parameters, ranked by impact, were determined as: scanning spacing = 0.12 mm, scan speed = 1.8 m/s, laser power = 16W, preheating temperature = 78 °C and layer thickness = 0.2 mm. These optimized settings significantly improved the mechanical performance of PSPC parts compared to other SLS parts produced under similar conditions. ANSYS simulations, conducted to validate these optimized parameters, showed minimal differences between simulated and experimental parts, confirming their reliability. Practical implications The parameters processing optimization of PSPC parts enhances PSPC’s suitability for use in wooden, roofing and furniture manufacturing. Originality/value This study integrates theoretical, experimental, simulation approaches and statistical analysis, ensuring the reliability of experimentally optimized PSPC SLS parameters and guaranteeing their future applicability.