Abstract: A polymeric article of high ductility is produced by rapid prototyping or selective laser sintering. The article includes a plurality of layers of a fused thermoplastic powder, the thermoplastic powder including asymmetric fibrous particles having a mean length L and a mean width W, wherein L>2W. Within each of the layers, the mean length L of the asymmetric fibrous particles is preferentially oriented in a plane parallel to the layer. The polymeric article may have a microtextured surface, and a stress-strain curve such that ultimate strength is reached at a strain of 10% to 20%, and breaking stress is reached at >30% strain.

Abstract: A polymeric article of high ductility produced by rapid prototyping or selective laser sintering, and a method of making the same. The article comprises a plurality of layers of a fused thermoplastic powder, the thermoplastic powder comprising asymmetric fibrous particles having a mean length L and a mean width W, wherein L>2 W. Within each of the layers, the mean length L of the asymmetric fibrous particles is preferentially oriented in a plane parallel to the layer. The polymeric article has a stress-strain curve such that ultimate strength is reached at a strain of 10% to 20%, and breaking stress is reached at >30% strain.

Abstract: A polymeric article of high ductility is produced by rapid prototyping or selective laser sintering. The article comprises a plurality of layers of a fused thermoplastic powder, the thermoplastic powder comprising asymmetric fibrous particles having a mean length L and a mean width W, wherein L>2W. Within each of the layers, the mean length L of the asymmetric fibrous particles is preferentially oriented in a plane parallel to the layer. The polymeric article has a stress-strain curve such that ultimate strength is reached at a strain of 10% to 20%, and breaking stress is reached at >30% strain.

Abstract: A three-dimensional object may be produced with improved dimensional control by laser sintering a polymer powder having a melting point and melting onset temperature, which has been annealed prior to sintering. The initial melting onset temperature of the polymer is between 50° C. and 170° C. The polymer powder is first annealed at a temperature which is below the polymer melting point, and from 5° C. above the melting onset temperature of the polymer powder to 10° C. below the melting onset temperature. Annealing may be carried out for a period of between 2 hours and 48 hours. A layer of the annealed polymer powder is applied to a carrier; and the layer is irradiated with a laser beam in areas of the layer which correspond to the three-dimensional object to be produced. The steps of applying the annealed polymer powder and irradiating the powder are repeated sequentially until the complete three-dimensional object is prepared.