Polyphenylene sulfide (PPS) is a high-performance engineering thermoplastic with a melting temperature of 285°C and excellent resistance to solvents, abrasion, and sunlight enabling use in electrical, automotive, and aerospace applications. In prior work, the authors demonstrated printing PPS via powder bed fusion (PBF) with bed temperatures near 200°C, well-below its melting temperature. To optimize final part properties, a statistical design of experiments analysis was performed to determine the influence of laser power, hatch spacing, and beam velocity on ultimate tensile strength and elongation for PBF-grade PPS. An L8 (23) Taguchi array was used for selecting experimental conditions, and enabling subsequent study of process variation due to laser processing parameters and their interactions. The
interaction of all three investigated terms represents energy density, a commonly used metric for predicting process parameter settings. Results suggest builds at the same energy densities, but different constituent parameters, may not produce comparable mechanical properties.