Selective Laser Sintering (SLS)
SLS – Layer-by-layer Additive 3D Printing Process
Selective Laser Sintering (SLS) is a layer-by-layer additive 3D printing process using powdered nylon. This material is sintered in slices by a high-powered laser to form functional end-use parts.
SLS Benefits
The process is ideal for creating prototypes, custom production parts, hinges, snaps, clips and/or parts exposed to high temperatures or caustic chemicals. Particularly when you need tough and geometrically complex components.
When using SLS 3D printing technology, your designs are not constrained by the need to adhere to draft angles and consistent thicknesses. This enables a number of design improvements over traditional part manufacturing. It also allows for lighter components, faster manufacturing, and the ability to produce multiple parts at the same time.
Materials Available.
DuraForm® PA Plastic
Durable polyamide (nylon) material for real-world physical testing and functional use.
3D Systems DuraForm PA Plastic for SLS is a durable thermoplastic with balanced mechanical properties and fine-feature surface resolution.
Duraform PA Plastic is ideal for real world functional testing and low to mid-volume production runs. Capable of meeting UPS Class VI.
Applications
- Complex, thin-wall ductwork
- Functional prototypes that approach end-use performance properties
- Appropriate for low- to mid-volume rapid manufacturing
- Medical applications requiring USP Class-VI compliance, or biocompatibility
- Motorsports
- Aerospace
- Housing and enclosures
- Impellers and connectors
- Consumer sporting goods
- Vehicle dashboards and grilles
- Snap-fit designs
- Parts requiring machining or joining with adhesives
Benefits
- Balanced mechanical properties
- Build prototypes that withstand functional testing
- Produce durable end-use parts without tooling
- Machinable and paintable for demonstration parts
Features
- Compliant with USP Class-VI testing
- Compatible with autoclave sterilization
- Good chemical resistance and low moisture absorption
Technical Specs
| Tensile Strength: | 43 MPa |
| Elongation at Break: | 14% |
| Flexural Strength: | 48 MPa |
| Impact Strength: | 32 J/m (notched Izod) |
| Colour: | White |
| Build Size: | 500x500x475 mm |
| Layer Thickness: | 0.1 mm |
For more technical data download the material data sheet.
DuraForm® EX Plastic
Manufacture tough, impact-resistant plastic prototypes or end-use parts requiring moulded-part performance and capable of withstanding harsh environments.
The DuraForm EX SLS material is an HDPE like Nylon blend with fantastic flexural strength making it one of the best rigid materials available today for creating functional snaps and living hinges. DuraForm EX is also, a good general prototyping material for fit form and functional applications.
Applications
- Complex, thin-walled ductwork
- Motorsports
- Aerospace
- Unmanned air vehicles (UAV)
- Housings and enclosures
- Impellers
- Connectors
- Consumer sporting goods
- Vehicle dashboards and grilles
- Bumpers
- Snap-fit designs
- Living hinges
Benefits
- Parts have the toughness of injection moulded ABS and polypropylene
- Functional prototypes can be tested in “real life” environments
- Complex end-use parts can be economically manufactured in low and medium volumes
Features
- Outstanding toughness
- Excellent impact resistance
- Repeatable mechanical properties
Technical Specs
| Tensile Strength: | 37 MPa |
| Elongation at Break: | 47% |
| Flexural Strength: | 42 MPa |
| Impact Strength: | 74 J/m (notched Izod) |
| Colour: | White or Black |
| Build Size: | 381x330x457 mm |
| Layer Thickness: | 0.1 mm |
For more technical data download the material data sheet.
DuraForm® GF Plastic
Accurate and repeatable parts that excels in load bearing applications at higher temperatures.
DuraForm GF is a glass-filled engineering plastic with high stiffness for durable prototypes and low to mid-volume production parts that require elevated stiffness and heat resistance.
Applications
- Housings and enclosures
- Consumer sporting goods
- Appropriate for low- to mid-volume rapid manufacturing
- Complex production and prototype plastic parts
- Form, fit or functional prototypes
- Parts requiring stiffness
- Thermally stressed parts
Benefits
- Excels in load bearing applications at higher temperatures
- Prototypes and end-use parts without tooling
- Accurate and repeatable parts
- Machinable and paintable for demonstration parts
- Improved isotropic shrinkage due to glass filler
Features
- Excellent mechanical stiffness
- Elevated temperature resistance
- Dimensionally stable
Technical Specs
| Tensile Strength: | 27 MPa |
| Elongation at Break: | 1.4% |
| Flexural Strength: | 37 MPa |
| Impact Strength: | 41 J/m (notched Izod) |
| Colour: | White |
| Build Size: | 381x330x457 mm |
| Layer Thickness: | 0.1 mm |
For more technical data download the material data sheet.
DuraForm® HST Composite
A fibre-reinforced material with an ideal mix of stiffness, strength and high temperature resistance.
DuraForm HST Composite is a fibre-reinforced engineering plastic with excellent stiffness and high temperature resistance, non-conductive and RF transparent. Ideal for testing and use in rugged environments.
Applications
- Functional prototypes and end-use parts that require high stiffness and/or elevated thermal resistance
- Typical Applications include:
- UAV structural components
- Housings and enclosures
- Impellers
- Connectors
- Consumer sporting goods
Benefits
- Functional prototypes can be tested in “real life” environments
- Complex end-use parts can be economically manufactured in low-to-medium volumes
- Excels in load-bearing applications at higher temperatures
Features
- High specific stiffness
- Elevated temperature resistance
- Anisotropic mechanical properties just like fibre-filled, injection moulded materials
- Non-conductive and RF transparent
Technical Specs
| Tensile Strength: | 48-51 MPa |
| Elongation at Break: | 4.5% |
| Flexural Strength: | 83-89 MPa |
| Impact Strength: | 37.4 J/m (notched Izod) |
| Colour: | White |
| Build Size: | 381x330x457 mm |
| Layer Thickness: | 0.1 mm |
For more technical data download the material data sheet.
DuraForm® PAx Natural
High impact, high elongation, high recyclability SLS material with properties similar to injection moulded nylon plastic for tough, lightweight, production-grade parts.
DuraForm PAx Natural is a nylon copolymer that offers properties similar to injection moulded plastic and features high impact resistance with high elongation at break in any direction, including Z. Engineered for easy processing and high recyclability, DuraForm PAx Natural is ideal for functional prototypes and end-use parts with good mechanical properties and long-term stability.
Applications
- General purpose prototypes
- Orthotics
- Tooling handles and grips for use in tough, rugged environments
- Living hinges
- Liquid reservoirs per data sheet specifications
- Enclosures requiring high impact and high toughness
Benefits
- Functional prototypes can be tested in “real life” environments
- Complex end-use parts can be economically manufactured in low-to-medium volumes
Features
- Excellent long-term stability; 5+ years indoor for mechanical properties and colour
- Vapor-polished parts have excellent translucency and smooth finish
Technical Specs
| Tensile Strength: | 40 MPa |
| Elongation at Break: | 282% |
| Flexural Strength: | 37 MPa |
| Impact Strength: | 41 J/m (notched Izod) |
| Colour: | White |
| Build Size: | 381x330x457 mm |
| Layer Thickness: | 0.1 mm |
For more technical data download the material data sheet.
PA 2210 FR
This white polyamide 12 powder is equipped with a halogen-free chemical flame retardant. Underwriters Laboratories (UL) has issued a Blue Card (equivalent to the well-known Yellow Card) specifically dedicated to 3D printing materials to PA 2210 FR: at wall thicknesses above 3 mm, it meets the required fire protection class UL 94 / V-0, primarily relevant for the production of electric and electronic components and applications in the aerospace and automotive sectors.
Applications
- Aerospace
- Electronics
- Automotive
- Lighting fixtures
Benefits
- Maintains high mechanical properties
- Safe to use in high risk applications
Features
- Contains a chemical flame retardant. In case of fire a carbonating coasting arises at the surface of the part, isolating the plastic below.
- Free of halogens
Technical Specs
| Tensile Strength: | 45 ±3 MPa |
| Elongation at Break: | 5.0 ±1 % |
| Flexural Strength: | 45 ±2 MPa |
| Colour: | White |
| Build Size: | 381x330x457 mm |
| Layer Thickness: | 0.15 mm |
For more technical data download the material data sheet.
Frequently Asked Questions (FAQ)
Selective Laser Sintering offers excellent material properties, including high mechanical strength and heat resistance. It’s well-suited for producing functional prototypes, end-use parts, and complex geometries without the need for support structures.
Selective Laser Sintering supports a wide range of materials, such as Nylon 11, Nylon 12, TPE, Copolymers and other blended Nylons (Glass, Carbon Fibre, Aluminium). The material choice depends on the application’s mechanical, thermal, and aesthetic requirements.
Yes, Selective Laser Sintering is known for its ability to produce intricate and complex designs that might be challenging with other manufacturing methods. Its layer-by-layer approach allows for the creation of detailed and precise geometries.
Selective Laser Sintering finds applications in industries such as aerospace, automotive, medical devices, prosthetics & orthotics, consumer goods, and more. It’s particularly valuable for creating functional prototypes and end-use parts with demanding performance requirements.
The cost of a Selective Laser Sintering project depends on factors like part size, complexity, chosen material, and quantity. Additionally, post-processing requirements and finishing options can also impact the overall cost.
One of the unique benefits of Selective Laser Sintering is that it eliminates the need for support structures during the printing process. This leads to reduced material wastage, simplified post-processing, and the ability to create intricate designs that might be impractical with traditional manufacturing methods. The elimination of supports also helps reduce the overall cost as build supports increase the amount of material required.
Yes, as with any 3D Printing solution, the maximum size of printed parts will vary depending on choice of material and corresponding printer. Formero’s largest SLS printer can accommodate part geometries up to 500 x 500 x 475 mm in one piece. Larger parts can always be printed in sections and joined afterwards.
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