Laser Micro Fabrication Using Green Tape.

The present paper proposes a new type of layer manufacturing of micro structural/functional parts using laser sintering. Technical innovation lies in the use of green tape made of micro powder, organic binder and solvents in a process based on conventional selective laser sintering. First, the process architecture is explained to differentiate the proposed method from others, then a feasibility investigation is discussed. Some metal powders, including copper, nickel and steel, have been sintered under various process parameters such as laser beam power, scan speed and scan spacing. Carefully controlling the parameters as well as the repeating deposition and pattern creation produces three-dimensional metal parts on a stainless steel substrate. Strength, density and microstructures are also examined to characterize the sintered parts. The copper object as sintered has a density of 4.5 g/cm3 and a maximum tensile strength of 40 MPa. A hybrid structure of steel and nickel can be fabricated through layering both powder tapes by turns.