The production of functional tool steel components by selective laser sintering requires
an understanding of the effects of the laser processing parameters on the microstructure
evolution during the fabrication process. This would allow the production of tools that have
predictable and reproducible microstructure, good mechanical properties and low residual
stresses. In this paper, finite element modelling has been carried out to investigate the
temperature distribution and residual stresses during laser sintering of hot-work tool steel
powders. The effects of the laser power and scanning rate on the selective laser sintering process
have been investigated. Thermal residual stresses accumulated during the process have been
predicted and compared with strain measurements made using neutron diffraction.