Optimization of polyamide 1012 powder for laser powder bed fusion via complexation with metal ions

Semi-biological polyamide 1012 (PA1012) possesses an overall performance comparable to that of polyamide 12 (PA12) and polyamide 11 (PA11). However, its unsuitable crystallization behavior greatly hinders its application in powder bed fusion with laser beam (PBF-LB/P). Herein, metal ions (Ca2+) were introduced to form complexation interaction between polymer chains aiming to optimize the processing behavior of PA1012 powder prepared via dissolution-precipitation and to improve the mechanical properties of fabricated parts. It was found that the complexation method and metal ion content were vital in controlling the morphology, flowability, melt rheology, crystallization, and other properties of PA1012 powder. The complexation-induced restriction in the chain mobility optimized the crystallization behavior, suppressed the post-condensation of powder during processing, and greatly improved the overall mechanical properties of the parts. This study elucidated the utilization of metal ion-polymer complexation interaction in regulating the structure-property relationship of polyamide powder and parts for the first time, shedding new light on expanding the material palette for PBF-LB/P.