Method for preparing fine powders for use in selective laser sintering processes

A process for preparing a feedstock with a plurality of polyaryletherketone (PAEK) particles for selective laser sintering, each of the plurality of PAEK particles within one of a plurality of particle size ranges, the process comprising the steps of:

• determining a particle size distribution of the plurality of PAEK particles in the feedstock based on respective numbers of the plurality of PAEK particles within each of the plurality of particle size ranges, the plurality of particle size ranges having at least three size ranges;
• identifying at least two of the plurality of particle size ranges having a depressed melting temperature relative to the average melting temperature of the plurality of PAEK particles in the feedstock based on the particle size distribution determination by number, and
• reducing the respective numbers of the plurality of PAEK particles in the feedstock within the at least two of the plurality of particle size ranges having a depressed melting temperature relative to the average melting temperature of the plurality of PAEK particles in the feedstock based on the particle size distribution determination to form a prepared feedstock, the at least two of the plurality of particle size ranges have a particle diameter of 20 microns or less;
• using the prepared feedstock in a selective laser sintering process comprising the step of applying a layer of the prepared feedstock on a bed of a laser sintering machine, solidifying selected points of the applied layer of the prepared feedstock by irradiation, successively repeating the step of applying the prepared feedstock and the step of solidifying the applied layer of the prepared feedstock until all cross sections of a three-dimensional object are solidified.