Selective laser sintering responses of keratin-based bio-polymer composites

Abstract Keratin-based materials have unique biological and mechanical attributes due to the protein's molecular structure and organisation. The current study evaluates the possible consolidation of keratin powders by selective laser sintering (SLS), a key enabler of additive manufacturing. The laser energy input became too intense for the thermally sensitive keratin powders. However, polymer keratin composites developed by blending with polyamide and polyethylene powders were evaluated and shown to be suitable for processing by SLS. Blends were thermally characterised to establish the initial process conditions. Morphological evaluation of the initial sintered samples allowed optimisation of the energy densities. Mechanical responses of the samples produced under these conditions were evaluated. Polymer-keratin composites were established as candidate materials for SLS. Critical attributes of these material combinations require further optimisation before these materials would be competitive in the market place.