What is SLS Printing?

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Selective Laser Sintering (SLS) is a method of Additive Layer Manufacturing (ALM) where a laser is used to fuse or sinter powdered material layer by layer to construct 3-dimensional forms.

The process starts by importing and nesting one or more CAD models in Formlab's slicer, Preform. Once arranged, the model/s are sliced into a series of cross-sectional XY layers defining the laser toolpath. These instructions are then sent to the printer.

Once a print has commenced, the build chamber will heat for ~45 minutes. After reaching the ideal operating temperature, a roller disperses several foundational layers of nylon powder to the build chamber.A laser beam is then directed at a motorized mirror and steered onto the powder surface, sintering the first cross-sectional layer of nylon. The build chamber is then lowered by one layer, and a fresh layer of powder is dispersed, ready for sintering. This sintering, lowering, and dispersing process is repeated until the entire build has been printed.

After printing, the build chamber will cool for several hours to ensure optimal mechanical properties and avoid warping in parts. Once cooled, prints can be removed from the build chamber, separated, and cleaned of excess powder. Prints are then media blasted before they are ready for collection.

As unsintered powder supports the parts during printing, no additional support structures are required enabling complex geometries (undercuts, interior features, integrated/ interlocking assemblies) to be printed with ease.