3D Multi‐Physics Finite Element Simulation of the Selective Laser Sintering Process for Polyamide 12: Effects of Laser Parameters on Melt Pool Formations and Sintering Quality

ABSTRACT Selective Laser Sintering (SLS) is an additive manufacturing method that enables the rapid and cost‐effective production of complex polymer parts with high strength and dimensional accuracy. However, achieving these improved properties depends on laser processing parameters, which significantly influence melt behavior, melt pool properties, and the overall quality of the components. Because empirical approach is both time‐consuming and cost‐intensive, finite element method (FEM)‐based simulations have become a popular field of study. However, existing simulation models are often oversimplified and inadequate to fully understand the multi‐physics nature of SLS. To address this gap, a comprehensive 3D multi‐physics finite element model was developed to simulate the SLS processing of Polyamide 12 powder. This study incorporates multiple interacting physical phenomena, such as heat transfer, fluid flow dynamics, melt‐solidification kinetics, and phase transformations, to provide a realistic depiction of the transient thermal and fluid behavior of the SLS process. The simulation systematically examined the influence of laser process parameters on molten pool formation, temperature distribution, and overall sintering quality. The results show that insufficient volumetric energy density (VED) or high scan speeds resulted in incomplete melting and porosity, whereas excessive energy input promoted overheating and material degradation.