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Selective Laser Sintering (SLS)

3D Prototype Design has been working with SLS technology since 1999 and as a result has built a strong reputation for providing exceptional nylon parts. SLS supplies the best that 3D printing can offer including durable, functional and flexible parts, multiple pieces as well as parts that can be tapped, drilled, snap-fit and sterilized.

SLS Printing Process

Selective Laser Sintering uses a CO2 laser to fuse powdered materials. As the laser contacts the powder bed, it raises the material to its sintering temperature to create a layer of solid part geometry.

  • STL CAD file is sliced to create layers
  • Laser draws the bottom-most layer
  • Powder is spread over completed layer
  • The process is repeated for subsequent layers
  • Upon completion, the powder cake is removed
  • Part is extracted from the loose powder
As the CO2 laser scans across the powder bed, it brings the material to the melting point. At this temperature, individual particles bond at their contact points to solidify a layer of the prototype. The depth to which the powder solidifies is a function of laser power and material sintering temperature. Solidifying a single layer is controlled by passing the laser over the powder bed at a speed that imparts the necessary level of energy.
Knex 3d printed close up
Mini mattress

SLS Printing
In Laymen’s Terms

In other words, in a computer software program we take your parts and slice them into layers that are .004” thick (approx. 2 hairs)*. The SLS machine is heated up, the building bed drops by .004” (one slice of your parts) and the roller lays out a layer of power material (such as nylon or rubber-like).

Here’s when the term selective laser sintering comes into play —  the laser then goes across the building bed area and selectively sinters (flash melts the slice) making the solid areas solid, one slice at a time. Whatever doesn’t get melted remains as a powder and acts as the support structure.

This process will continue layer by layer until the parts are done. Once the build is complete and the bed has cooled down, a technician removes the block of powder; digs through it like an archaeological dig to find the solid pieces, then removes and cleans away the loose powder around the parts. The parts are now ready for use or post-colouring.

SLS Printing Advantages:

  • Fully functional, durable prototypes (like an injection molded plastic part when nylon is used)
  • Nylon material parts can be tapped, drilled, snap fit, assembled and painted
  • Living hinges and functioning springs can be produced, fluids can be run through them
  • Rapidly produces one or multiple pieces (up to hundreds or thousands, dependent on size)
  • In addition to nylon, this process also offers glass-filled nylon, carbon fiber, rubber-like and metal materials

*3D Prototype Design builds only at 0.004” to offer the best resolution available to our customers. The typical layer thickness for the Selective Laser Sintering process is between 0.004” and 0.006”

To learn more about the various 3D printing technologies that are available to you or to determine whether SLS printing is the best method for your prototype, please contact us for more information or request a quote.

FAQs
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What do I need to make a 3D printed part?

In order to quote or make a 3D printed part, you need to have a 3D CAD file drawing created. We do not offer drawing or scanning services. If you don’t have a CAD drawing of your part you should find a mechanical engineer/design to draw your part. See what is 3d printing.

We’ve built parts for as low as $3 per piece and up, when building multiples. However, each case is unique and dependent on several factors such as: size, area, volume, material used, time to build, commitment to area taken up, labor and what else we can build with it. Our minimum charge is $100.
We don’t like to ballpark pricing unless it’s coming from an existing customer. A guess can sometimes be made, however, you will need a CAD file to move forward and it’s very likely the cost of hiring someone to do the drawing may very well be more than your prototype. Asking how much something the size of a mug or computer mouse will cost rarely offers any value. Start by looking at the cost to get your CAD drawing first to see if that’s cost prohibitive for you.
Hire a mechanical engineer or mechanical designer as they can create 3D CAD drawings. In addition, their education and experience will be valuable later should you manufacture your parts.

We sure can. Whether is a scaled down model for a trade show or for a sales meeting, our 3d printed models can’t be beat! There are some very important things you should quick read first though to better understand what you need to know about 3d printing and your scaled down model.

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