Selective laser sintering is an additive manufacturing technique that uses a high power laser to sinter or melt powder layer by layer to build 3D shapes. This paper focuses on creating a mathematical model of the crack width and surface roughness that occur during the selective laser sintering process. Response surface methodology is used to build and determine a mathematical model. Five variables at five levels are selected: forward step, side step, speed, platform temperature and layer depth. Based on response surface methodology, 32 experiments are used to determine the mathematical model of two selective laser sintering defects: crack width and surface roughness. Next, a genetic algorithm is used to determine the optimal solution to minimize crack width and surface roughness of the part. Results show that the five selected parameters have an effect on the target defects as confirmed by the resulting main effects plots, interaction plots, and contour plots. An optimal set of parameters is determined for future use.

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