SLS Selective Laser Sintering Service
Selective Laser Sintering (SLS) is an advanced 3D printing technology that uses a high-powered laser to fuse powdered materials, typically nylon, layer by layer to create solid parts.
Why use SLS 3D Printing?
SLS Printing This is well-suited for producing complex geometries and high-quality functional prototypes without needing support structures. Use case scenarios include manufacturing durable automotive and aerospace components, creating lightweight yet strong parts for medical devices, and rapid prototyping for product development. SLS is also utilised for producing end-use parts and low to medium batch production runs in various industries due to its capability to deliver high-strength, mechanically robust parts.
Benefits of SLS Printing
Benefits
- No support structures needed in the design
- Allows for complex geometries
- Possible to produce very strong, light parts
Best suited for
- Production parts
- Complex builds
- Engine air intakes
- Brackets and clips
- Brake ducting
- Drone fuselages
Materials for SLS
- Carbon SLS
- Graphite SLS
Selective laser sintering (SLS), produces tough parts with high temperature resistance that are stable over time. SLS is often the technology we use for producing end-use parts. We have also developed sealing techniques to make our parts air tight, and water or chemical resistant.
To ensure your components have the mechanical properties you have specified, we build and test mechanical test bars on every SLS build. The mechanical data we publish is always from actual results, as opposed to taken from the manufacturers’ data sheets.
High Complexity and Design Freedom
- SLS allows for the creation of intricate, complex geometries that would be challenging or impossible to achieve with traditional manufacturing methods.
- The technology does not require support structures, enabling designers to innovate freely without producing extra waste.
Durable and Functional Parts
- SLS produces high-strength, durable parts suitable for both prototypes and end-use applications.
- The process uses robust materials such as nylon, which impart excellent mechanical properties to the finished parts.
Cost-Effective for Low to Medium Batch Production
- SLS is ideal for economically viable production runs, allowing for efficient manufacturing without the need for expensive molds or tooling.
- The process supports rapid iteration and customization, reducing lead times and costs associated with product development.
Applications
Applications in high-performance industries:
Motorsport
- SLS is utilized to produce lightweight and robust components such as air ducts, brackets, and mounts that contribute to the reduction of vehicle weight, enhancing speed and fuel efficiency.
- Custom cooling ducts, brackets, and housings.
Marine Racing
- SLS allows for the fabrication of complex hydrodynamic parts such as propellers, fins, and rudder components. These parts are designed to optimize water flow and improve performance by reducing drag.
- Components such as casings, housings, and protective covers are created to withstand the rigors of marine racing while maintaining performance and longevity.
Advantages
Engineering advantages:
Functional Prototypes and End-Use Parts
Engineers use SLS to rapidly prototype intricate components like suspension parts, engine covers, and interior parts that need to withstand high temperatures and mechanical stresses.
SLS parts can be used directly in the vehicle for testing or end-use, saving time and costs by bypassing traditional manufacturing steps.
Rapid Iteration and Testing
SLS enables marine engineers to quickly produce and test new designs, allowing for rapid iterations and optimizations. This is particularly useful for parts that need to meet specific hydrodynamic requirements.
The SLS process overview
The SLS process uses a bed of powdered material which is fused a layer at a time by a high power, CO2 laser.
The laser ‘draws’ a single layer cross-section of the required part on the surface of the powder bed, accurately creating the part layer and joining it to the layer below.
When each layer has been completed, the powder bed lowers and the process is repeated one layer at a time until the required object is complete. During construction, an object being built by SLS is supported by the surrounding powder – it is possible therefore to build very complex geometries without any need for interfering support structures. In this way the SLS process allows previously impossible shapes to be built.
Preparation
A bed of powdered material is evenly spread.
Laser Sintering
A high-power CO2 laser traces and sinters each cross-section of the part.
Layer-by-layer Construction
The powder bed lowers, and new layers are added and sintered until the part is complete
Post-processing
Parts are cooled and undergo additional finishing processes to achieve desired mechanical properties and surface quality.
