Multilayer polymer structures containing Ni/Cu nanoclusters as prepared by selective laser sintering

Selective laser sintering (SLS) process was used to prepare nanostructured porous 3D items consisting of Ni or/and Cu nanoclusters embedded into a polycarbonate (PC) matrix for potential use in nanoelectromechanical systems (NEMS). Liquid-phase SLS was performed (in air or Ar) with the Ni-PC powder mixtures taken in proportions of 1 : 1, 1 : 2 (Ni particle size 27–184 nm) and Cu-PC powder mixtures (1 : 9, 1 : 4, 3 : 7, Cu particle size 76–90 nm) using a cw YAG : Nd+3 laser (P = 4–10 W) and a scanned spot of slightly defocused beam. After sintering, the size of starting nanoparticles remained unaffected. Demonstrated was the feasibility of SLS production of functionally graded 3D items, which opens up a way to direct synthesis of NEMS devices. Process conditions for preparation of monolayers and 3D items were optimized. Functionally graded 3D items with alternating ferromagnetic Ni-PC and non-magnetic Cu-PC layers exhibited interesting electrophysical and magnetic properties.