SLS, or selective laser sintering, is a type of 3D printing that uses a laser to fuse together powdered materials, such as plastic or metal, to create a finished product. This process allows for the creation of highly detailed and complex parts and objects that would be difficult or impossible to create using traditional manufacturing methods.
SLS 3D printing is particularly useful for creating prototypes, small batch production runs, or custom products. Industries such as aerospace, automotive, and healthcare are already utilizing SLS 3D printing in their production processes, and as the technology continues to improve, it’s likely that we’ll see even more widespread adoption in the future.
In this post, we’ll be providing a detailed overview of the SLS 3D printing process, including the equipment and materials used, as well as the benefits and limitations of the technology.
SLS Printing – What Is It?
Selective Laser Sintering (SLS) is a cutting-edge 3D printing technology that utilizes a laser to fuse powders of various materials into solid objects. The most commonly used powder for SLS printing is a nylon-based material, but other powders can also be used.
The SLS printing process begins by laying down a thin layer of powder on the build platform of the printer. A laser is then directed onto specific areas of the powder, selectively melting and fusing it together to form the object. This process is repeated layer by layer until the entire object is complete. The result is a high-quality, detailed and robust 3D object that is often suitable for functional parts, engineering and end-use products.
One of the major advantages of SLS printing is its speed, precision and cost-effectiveness in producing complex and detailed parts. It opens up opportunities for manufacturing highly customized and intricate objects that are not possible with traditional manufacturing methods.
Benefits Over Other 3D Printing Technologies
SLS 3D printing has several key benefits over other 3D printing technologies. The following are the most important ones:
- The parts printed using SLS are much more durable and have higher strength than parts produced using filament-based 3D printers.
- SLS produces finer details in its prints – far better than any filament-based printer can achieve.
- SLS 3D printing does not require additional support material, meaning that complex geometries and hollow parts are produced without added support.
- SLS is a much faster process than other types of 3D printing – making it ideal for mass-produced items.
What Is the SLS Printing Procedure?
A laser is used in SLS 3D printing to sinter tiny polymer powder particles. The component’s whole cross-section is scanned, ensuring sturdy construction. The procedure goes like this:
Pre-treatment
The pre-treatment stage involves the application of a binder material to the powder, which acts as a glue between the particles and helps the powder hold its shape during the printing process. The binder also helps the material to stick to the build platform, allowing for a consistent print.
Deposition
Laser scanning of the powder print bed to uniformly heat areas of it depending on the shape of the part being printed while a thin layer of powder is applied on the build platform by a re-coating blade.
Fusing
The polymer powder particles are then selectively melted or sintered together with heated particles by a powerful laser beam (using a CO2 laser) as it scans the outline of the subsequent layer to form solid parts.
After each layer is completed, the build platform descends, and the blade paints the surface in more layers. The procedure is repeated as soon as the entire section has been finished.
Post-processing
This step can involve removing support structures, cleaning, and surface smoothing to dyeing and coating with resins or paints. The pieces are entirely enveloped in unsintered powder after printing. Before the pieces are unpacked, the powder bin must cool, which can take a long time—sometimes up to 12 hours.
The items are then prepared for usage or additional post-processing after being cleaned using compressed air or another blasting medium.
Materials Used for SLS Printing
The 3D printing materials most commonly used with SLS are thermoplastic polymers such as nylon, polystyrene, and polycarbonate. Metals, glass, and sand can also be utilized in this process.
Although these materials have varying properties that can affect the strength of the final product, the result is usually more durable than parts produced on filament-based 3D printers.
Nylon, a highly capable engineering thermoplastic for functional prototype and end-use manufacturing, is the most often used due to its ideal sintering behavior and mechanical properties. Nylon is perfect for durable parts with excellent environmental durability and intricate assemblies.
SLS 3D-printed nylon components are robust, stiff, stable, and long-lasting. The finished components can withstand a lot of adversities, as they possess capabilities such as; repeated wear and tear resistance, impact resistance, chemical resistance, heat resistance, and temperature resistance.
Additionally, 3D-printed nylon components may be biocompatible and non-sensitizing, making them suitable for wear and risk-free in various applications.
These nylons are of various types and suitable for different functions.
Nylon 12 Powder
High detail, multipurpose material with excellent dimensional precision. best for;
- Fast prototyping
- Small-batch production
- Permanent fixtures, tooling, and jigs
- Basic SLS components
Nylon 11 Powder
Durable, robust, flexible material for situations where performance and longevity are essential. Best For;
- Prototypes, jigs, and fixtures that can withstand impacts
- Enclosures and ducts with thin walls
- Hinges, snaps, and clips
- Prosthetics and orthotics
Nylon 12 GF
A polymer with glass filling that has improved thermal stability and rigidity for harsh industrial situations. Best for;
- Dependable fixtures, jigs, and replacement parts
- Parts that are being loaded continuously
- Sockets and threads
- Parts that have been heated up
Powder Nylon 11 CF
This incredibly stable, lightweight, high-performance material combines the most remarkable qualities of carbon fiber with nylon. Best for;
- Alternatives to metal parts for replacement and spares
- Fixtures, jigs, and tooling
- High-impact tools
- Composite prototypes that work
Other materials that exhibit similar mechanical properties ideal for the SLS 3D printing process include Polyamide 12 and 11, Aluminum-filled nylon, Glass-filled nylon (PA-GF), Carbon-fiber nylon (PA-FR)
SLS 3D Printing Applications
Engineering
Take charge of the entire product development process, from the initial concept design iteration to the production of finished goods:
- Quick and Useful Prototyping
- Mockups of items for field feedback from customers
- Rigorous product functional testing (e.g., ductwork, brackets)
Manufacturing
Own your supply chain and act rapidly in the face of shifting consumer needs:
- Manufacture of End-use parts
- Bridge, stop-gap, and small-batch manufacturing
- Frequently customized consumer goods
- Spare parts, aftermarket parts, and replacement parts
- Tools, jigs, and fixtures (such as clips and clamps) that are long-lasting and robust
- Customized motorbike or auto parts, maritime gear, and military “resupply on demand.”
Healthcare
Produce in-house, patient-specific, ready-to-use medical devices:
- Prototyping of medical devices
- Orthotics and prosthetics (braces and limb replacements)
- Surgical tools and models
- End-use parts (Nylon 12 Powder is sterilization compatible and biocompatible)
Advantages of SLS 3D Printing
- High accuracy and detail: SLS 3D printers precisely produce intricate components with high resolution.
- Since the process is fast and efficient, it can be cost-effective for quickly producing small batches of parts or prototypes.
- It supports a wide range of thermoplastic polymers and metals, making it suitable for various applications and end-use productions.
- The end product is usually more durable than parts produced on filament-based 3D printers as the materials used are more robust.
- The granular form of the materials used for SLS 3D printing makes them flexible to use with diverse shapes and sizes.
- SLS 3D printing is a non-toxic process and does not produce any hazardous waste as it uses powder instead of filament spools available for reuse.
- It can produce complex parts with intricate geometries and internal channels that would otherwise be difficult or impossible to make.
- The entire process is automated so that the turnaround times will be significantly faster than traditional manufacturing methods like injection molding.
- Parts produced via SLS 3D printing require minimal post-processing and can be used almost immediately.
- The process is easily scalable, allowing for quickly producing low volumes or prototypes up to large batches of parts.
- SLS components are excellent for functioning parts and prototypes due to their isotropic mechanical characteristics.
- SLS does not require any support, making building designs with complex geometry simple.
- SLS has strong manufacturing capabilities for small- to medium-sized series production batches.
- The residual excess powder that wasn’t sintered is collected and can be utilized again.
Disadvantages of SLA 3D Printing
- The equipment and materials used for SLS 3D printing can be costly, making it out of reach for most smaller companies.
- Although a wide range of thermoplastic polymers is available, certain metals and composites still need to be supported.
- Parts produced via SLS 3D printing can be delicate and prone to breakage due to their granular construction.
- Complex shapes may require additional support structures, which can add cost and complexity to the process.
- Due to the lengthy process, it may be difficult to achieve tight turnaround times for production runs.
- The parts produced via SLS 3D printing have low resolution compared to other 3D printing processes such as SLA or FDM.
- Post-processing may be necessary if a smooth surface or water tightness is necessary because SLS products have a grainy surface finish and internal porosity.
- Printing small holes and large flat surfaces may be impossible with SLS because they are prone to warping and over-sintering.
FAQs on What is SLS 3d printing
The main difference between SLS and SLA is the type of materials that are used for production. SLS uses a bed of powdered material heated and fused, while SLA uses a liquid resin, which hardens when exposed to ultraviolet light. SLA is better for precise, detailed items, while SLS is better for functional, strong parts.
Yes, SLS 3D printing is suitable for rapid prototyping due to its fast turnaround times and ability to produce complex structures with tight tolerances. It is also suitable for low-volume production, as parts are produced quickly and efficiently in batches of any size.
Yes, SLS 3D printing is suitable for low-production runs as it can produce parts quickly and efficiently in batches of any size. Additionally, the materials used for SLS 3D printing have a long shelf life, meaning they can be stored and reused if needed.
The three main types of 3D printing are Fused Deposition Modeling (FDM), Stereolithography (SLA) and Selective Laser Sintering (SLS). FDM is the most widely used type of 3D printing, where thermoplastic filament is heated and extruded layer by layer to form a model.
The cost of SLS 3D printing can vary depending on the type and size of parts being produced and the material used. Generally speaking, the cost of SLS 3D printing is slightly higher than other 3D printing processes, such as FDM or SLA, due to its more advanced technology and materials.
Conclusion
SLS 3D printing is a cutting-edge technology with many potential applications. Its ability to produce complex structures with tight tolerance and fast turnaround times makes it an ideal choice for rapid prototyping, low-volume production runs, and even home users looking to get into 3D printing.
SLS may be the right choice for you if you’re looking for a high-quality, versatile 3D printing solution. With its long shelf life materials and cost-effective pricing, SLS 3D printing is an excellent investment for businesses looking to create detailed and intricate products.
