Selective Laser Sintering

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.

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

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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: 380x380x250 mm
Layer Thickness: 0.1 mm
Build Size: 500x500x475 mm
Layer Thickness: 0.1 mm

For more technical data download the material data sheet.

Download: DuraForm® PA Plastic Datasheet

DuraForm® EX Plastic

Manufacture tough, impact-resistant plastic prototypes or end-use parts requiring molded-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’s)
  • 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 molded 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

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Technical Specs

Tensile Strength: 37 MPa
Elongation at Break: 47%
Flexural Strength: 42 MPa
Impact Strength: 74 J/m (notched Izod)
Colour: White
Build Size: 381x330x457 mm
Layer Thickness: 0.1 mm

For more technical data download the material data sheet.

Download: DuraForm® EX Plastic Datasheet

DuraForm® ProX® FR1200

A flame-retardant nylon 12 material with high accuracy and excellent surface finish. Ideally suited for direct 3D production in aerospace, transportation and consumer goods applications where reliable fire retardancy and reduced smoke and toxicity are required.

DuraForm® ProX® FR1200 delivers highly accurate flame retardant nylon parts with excellent surface quality for aerospace, transportation and consumer goods applications. Compliant with U.S. Federal Aviation Regulation 25.853 and within Airbus Industries Test Method (AITM) guidelines for smoke density and toxicity, DuraForm ProX FR1200 introduces direct 3D production in aerospace to accelerate part delivery and reduce downtime. DuraForm ProX FR1200 is a non-halogenated Nylon 12 material.

Applications

  • Direct 3D production of aircraft interior parts
  • Parts requiring flame retardancy
  • Automotive and transportation related parts where fire safety may be needed
  • Consumer electronics and other goods

Benefits

  • Reduce fuel costs with weight optimized design enabled by additive manufacturing
  • Accelerate changes in cabin designs for in service aircraft
  • Eliminate tooling and minimize spare part stocking costs
  • Excellent flame retardancy at 12 and 60 second exposures

Features

  • FAR 25.853 compliant
  • Passes AITM smoke density and toxicity requirements
  • High accuracy and repeatability needed for manufacturing
  • Non-halogenated formulation
  • Excellent surface quality

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Technical Specs

Tensile Strength: 41 MPa
Elongation at Break: 5.9%
Flexural Strength: 62 MPa
Impact Strength: 25 J/m (notched Izod)
Colour: White
Build Size: 381x330x457 mm
Layer Thickness: 0.1 mm

For more technical data download the material data sheet.

Download: DuraForm® ProX® FR1200 Datasheet

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

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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.

Download: DuraForm® GF Plastic Datasheet

DuraForm® HST Composite

A fiber-reinforced material with an ideal mix of stiffness, strength and high temperature resistance.

DuraForm HST Composite is a fiber-reinforced engineering plastic wih 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 fiber-filled, injection molded materials
  • Non-conductive and RF transparent

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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.

Download: DuraForm® HST Datasheet