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Selective Laser Sintering, SLS

Selective Laser Sintering (SLS) is a layer additive production process that creates three dimensional objects using a CO2 laser to melt, or sinter, and fuse selective powder molecules based on information supplied by a computer aided design (CAD) file. Selective laser sintering (SLS) was born out of the University of Texas and is a popular process used in rapid prototyping and product development. The selective laser sintering (SLS) technology was brought to the forefront of commercialization by DTM Corporation which is now called 3D Systems. The powder material that is fused during the selective laser sintering (SLS) process is commonly called thermoplastic material or, in some cases, thermoplastic binders for use in metals. The selective laser sintering (SLS) technology allows for these materials to be fused together in tiny layers ranging between .003” and .006”. This allows selective laser sintering (SLS) to create parts with accurate details and tolerances comparable to stereolithography (SLA). However, selective laser sintering (SLS) has an added benefit in that the strength and durability of the parts it creates is much better. Additionally, the selective laser sintering (SLS) process makes parts that have longer stability than stereolithography (SLA) and selective laser sintering (SLS) parts won’t lose their shape or post cure over time.

There are a variety of different types of materials available for use in the selective laser sintering (SLS) process. The most beneficial characteristic of selective laser sintering (SLS) is how durable and functional the materials are. These durable and functional selective laser sintering (SLS) materials include DuraForm and DuraForm glass-filled (GF) which are nylon based materials that create plastic prototypes. Other selective laser sintering (SLS) materials are CastForm used for investment casting patterns, selective laser sintering (SLS) Flex for elastomeric, rubber-like parts, and selective laser sintering (SLS) LaserForm which makes metal prototypes. Additionally, there is continual research and development going on to bring new selective laser sintering (SLS) materials to market. Each of these selective laser sintering (SLS) materials requires little to no post build processing to be ready to use which cuts out several steps in post processing of selective laser sintering (SLS) parts as compared to stereolithography (SLA). However, all of the selective laser sintering (SLS) materials can be finished in multiple ways to meet the desire or needs of selective laser sintering (SLS) users. Among other types of post processing, selective laser sintering (SLS) parts can be sanded, painted, plated, tapped, or even machined. This allows for a higher grade of smoothness and appearance to selective laser sintering (SLS) parts and assemblies and also gives users an unlimited number of ways to use selective laser sintering (SLS) parts.

Other advantages of selective laser sintering parts (SLS) are:

Parts and/or assemblies that move and work that have a good surface finish and feature detail
Selective laser sintering (SLS) gives the capability of flexible snaps and living hinges as well as high stress and heat tolerance
Wide variety of materials such as flexible and rigid plastics, elastomeric materials, fully dense metals and casting patterns
Tight dimensional tolerances all the way down to thousandths of an inch
Finishing capabilities that include painting for presentations, tapping or threading for use and inserts for assemblies
Rapid delivery time of most parts and/or patterns in a few days

Since being patented in 1989, the selective laser sintering (SLS) technology has become one of the most utilized processes for prototyping and product development in all industries. Selective laser sintering (SLS) equipment and machinery have also developed and expanded to meet the needs of users. Currently, there are five different types of selective laser sintering (SLS) machines in circulation including high speed and high-q selective laser sintering (SLS) systems. Some of these selective laser sintering (SLS) systems have round platforms while others have square and rectangular build areas. The selective laser sintering (SLS) build platforms range in size from small (12” in diameter), to medium (12” x 14” rectangle), all the way up to the largest platform (20” x 20” square). The different size build areas allow selective laser sintering (SLS) users to choose how parts are built and oriented depending on how large or small the parts are designed. If parts exceed the parameters of the build area it is not difficult to build parts in the selective laser sintering (SLS) process in multiple sections and then bond them in post production. The variety of properties that selective laser sintering (SLS) materials offer makes it quite easy to bond sectioned parts together with an adhesive that is strong and tough. The selective laser sintering (SLS) process is able to produce parts and/or prototypes that fit a wide range of different applications. The most widely used application of the selective laser sintering (SLS) process is functional prototypes. The selective laser sintering (SLS) DuraForm PA and DuraForm GF are the most popular material choices for functional prototypes. These selective laser sintering (SLS) thermoplastics give you a choice of a durable and flexible plastic or a stiff and rigid plastic that have properties very close to an injection molded part. Parts created with these two selective laser sintering (SLS) materials are ideal for end users to test for form, fit, and/or function. Other than functional prototypes, selective laser sintering (SLS) parts can be used as models. Whether it is a presentation model for marketing purposes or a show piece for display, selective laser sintering (SLS) produces parts that can serve quite well as models. These selective laser sintering (SLS) parts usually require a highly aesthetic finish which is often called a master finish. Master finishing is a post production process that calls for the selective laser sintering (SLS) parts to be sanded extra smoothly and can even be primed, plated or painted to the end users desire. Yet another regular application that utilizes the selective laser sintering (SLS) technology is casting patterns. The selective laser sintering (SLS) CastForm material is the material of choice when creating patterns for investment casting in the selective laser sintering (SLS) process. This selective laser sintering (SLS) material is easily burned out in the foundry process making it a preferred material for investment casting patterns. The selective laser sintering (SLS) CastForm material is a poly-styrene that is coated with wax to solidify the pattern after being built in the selective laser sintering (SLS) machine. Once at the foundry the selective laser sintering (SLS) pattern is melted away prior to pouring the molten metal. The selective laser sintering (SLS) process is ideal for investment casting because it is capable of making patterns with high accuracy and intricate detail.

Over the years the selective laser sintering (SLS) process has evolved into a common option for the creation of end-use production parts. The large assortment of different plastics and metals have made it quicker and less costly to use selective laser sintering (SLS) as opposed to other methods of manufacturing such as tooling. Selective laser sintering (SLS) is especially attractive when a design is complex or customized and the total part production requirements are low. Finally, the selective laser sintering (SLS) technology is well suited for use in rapid tooling. Rapid tooling, or RT, is generally different from conventional tooling in the following key areas:

Rapid tooling is generally produced faster than conventional tooling, taking off as much as 80-90% of the time it takes to create first parts. This is where the speed of selective laser sintering (SLS) comes into play as parts can be created in days as opposed to weeks
Rapid tooling is typically delivered at a lower cost compared to conventional tooling – as much as 90-95% less
Tolerances for rapid tooling are usually not as accurate as conventional tooling but selective laser sintering (SLS) allows for customization of specs to meet customer needs
Rapid tooling life is considerably less than a conventional tool

In spite of these differences, for many applications, rapid tooling using the selective laser sintering (SLS) process is ideal for first run parts or short run prototype production until conventional tooling methods can be obtained. Selective laser sintering (SLS) is an avenue that cuts a products time to market down considerably and, since the process can be customized, allows for design changes to be made without having to create a new tool. Harvest Technologies has multiple options for selective laser sintering (SLS) rapid tooling, as well as others, so please allow us to consult with you on the best choice for your requirements.