OVERVIEW

Selective Laser Sintering (SLS) produces rapid prototypes from production materials and their parts typically have the highest strength. A CO2 laser sinters powdered material layer by layer to create a durable, solid object. The sintered prototype can be used for functional testing in almost all applications including functional prototypes, electronic packaging, high-temperature components, snap fits, living hinges because they are constructed from real engineering materials.

When part durability or high heat deflection temperatures are required, SLS can produce parts which closely represent the physical properties of the production material.

 

PROCESS

Step 1 : The Preparation

SLS begins with a 3D CAD file that is oriented in the appropriate orientation for building the part. The file is mathematically processed into 2D cross sections (layers) along the Z-axis.

Step 2 : The Build

A SLS machine consists of two powder magazines on either side of the fabrication area. The entire build chamber (powder magazines and fabrication area) is heated to a temperature just below the melting point of the powder. This is done so that heat from the laser only needs to elevate the temperature slightly to cause sintering.

The leveling roller pushes powder from one magazine picking up material and over onto the build area, depositing material. It then continues to the other magazine.

A CO2 laser beam steered by a scanning system draws the 2D cross section on the surface of the build material, sintering the powder. The platform then descends a layer thickness. The leveling roller pushes material from the powder cartridge across the build platform, where the next cross section is sintered to the previous. This continues until the part is completed

Step 3 : The Completion

After the object is fully formed, the piston is raised to elevate it. Excess powder is brushed away and final manual finishing may be carried out. No supports are required with this method since overhangs and undercuts are supported by the solid powder bed.

 

APPLICATIONS

• Limited number of prototypes needed (1-10)
• Form and fit testing
• Functional testing
• Field testing