Selective Laser Sintering (SLS) is an additive manufacturing technology used to create strong plastic parts. Similar to PolyJet and SLA, the SLS process quickly turns 3D CAD data into physical parts and prototypes. SLS, however, uses powdered Nylon 11 and Nylon 12 polyamide materials along with property enhancing fillers. Parts produced are light-weight, highly durable, and both heat and chemical resistant, making SLS an excellent choice for producing parts without the expense of hard tooling.
Since SLS parts are made from more than just a prototyping plastic, they are being used for a variety of end-use and functional parts including: medical tools and fixtures, fuel tanks, flight rated components for unmanned vehicles (UAV’s and UGV’s), robust automotive designs, architectural models, and environmental control system air-ducts.
The SLS process begins like other additive manufacturing processes, splitting the 3D CAD data into thin 2D layers. Once the data is transferred to the machine, a leveling roller deposits a thin layer of powdered material across a powder bed. A CO2 laser then traces a specific pattern designated by the 3D CAD data upon the material. As the laser scans the surface, material is sintered (heated and fused) together. Once a single layer is complete, the powder bed is lowered just enough to make room for the next layer. More material is raised from the powder cartridge and rolled out smooth, while unused material is recycled. The process is repeated, building layer upon layer until the part is complete.
As SLS parts are built, they are encompassed by unsintered powder providing supplemental strength. Support structures are not necessary in SLS as they are in PolyJet and SLA. Consequently, difficult designs once thought impossible with other processes can be fully realized with SLS.
Due to the nature of the SLS process, assemblies typically requiring multiple components are being redesigned as integrated structures. Unitized SLS assemblies reduce assembly cost and increase part strength. Additionally, SLS parts can be created from a range of powder materials, including Nylon-11 and Nylon-12 polyamides, nylons with fillers such as glass beads, and nylons reinforced with aramid or carbon fibers that substantially enhance physical properties.
Basic coloring of SLS parts is now available with Solid Concepts’ proprietary ColorTek process. ColorTek is an excellent alternative to paint for parts requiring non-cosmetic color. This colorizing process is particularly useful for making standard black SLS materials look richer and darker in color. Standard colors available with ColorTek are red, orange, yellow, green, blue and black. Further finishing options such as EMI/RFI shielding, Exo-Skeletal Metal Strengthening as well as Cosmetic Paint are available to bring your part to completion.
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