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This paper aims to describe a new process for suppressing the formation of orange peel, which is a polymer laser sintering (LS) process error.

The target for controlling the suppression of orange peel is securing the contact between the molten polymer and the surrounding powder. The authors set the powder bed temperature closer to the melting temperature than that for a typical LS. Alternatively, the authors use a low-power laser to irradiate the powder bed surrounding the parts being built. The surface finish of the built parts was evaluated using a three-dimensional scanner.

Both approaches were effective in suppressing orange peel. From the viewpoint of reusability of the used powder, the process that includes low-power laser irradiation is practical. The presence or absence of contact between the surrounding powder and the molten polymer determines whether the orange peel is formed.

The authors have not tested orange peel suppression for complex shapes.

The authors have demonstrated a concrete process that can suppress orange peel formation even for powders with low melt-flow rates. Furthermore, a mechanism for the formation/suppression of orange peel based on the experimental results was proposed.