Abstract: A process for preparing a feedstock having polyaryletherketone particles for using in selective laser sintering. The process includes the steps of determining a particle size distribution of the polyaryletherketone particles in the feedstock based on a number of particles corresponding to each of a plurality of particle size ranges to obtain a particle size distribution determination. The process further includes the step of reducing the number of particles in the feedstock corresponding to one or more size ranges having a depressed melting temperature relative to the average melting temperature of the polyaryletherketone particles in the feedstock based on the particle size distribution determination.

Abstract: The method includes the steps of functionalizing a polyaryletherketone (PAEK) polymer, and blending the PAEK polymer with water to form a sizing composition. The method may further include the step of applying the sizing composition to a fiber. The method may further include the step of heating the fibers, coated with sizing composition, for example to between 300C-400C. In some methods, the functionalized PAEK polymer comprises functionalized polyetherketoneketone (PEKK). In yet other methods, the functionalized PAEK polymer comprises sulfonated PEKK (sPEKK).

Abstract: A method for determining a bed temperature setpoint for use with a powder in a selective laser sintering machine is disclosed. The method includes the step of providing a powder comprising a polymer for use in a selective laser sintering machine. The method further includes the step of determining a ratio of a liquid portion of the powder to a solid portion of the powder as a function of temperature within a temperature range. A bed temperature setpoint is selected in the temperature range corresponding to a desired ratio of the liquid portion of the powder to the solid portion of the powder. A temperature of a bed of a selective laser sintering machine is set to the selected bed temperature setpoint, and a part is built from the powder using the selective laser sintering machine.