SLS 3D Printing Applications

You can create a solid three-dimensional object from three-dimensional digital models using several additive manufacturing or 3D printing technologies. Each 3D printing technology creates the object, model, part, or product physically in a specific way. Selective Laser Sintering (SLS) is one of the mature and widely used 3D printing technologies.

As the name suggests, this additive manufacturing technology creates solid parts by fusing or sintering nylon powder selectively using a high-power laser. Many engineers opt for SLS 3D printing to produce strong and durable parts with complex geometries. Also, they can enhance the look and feel of the 3D-printed structures during post-processing through sanding, dyeing, and smoothing.

Both companies and startups have been transforming and revolutionizing SLS 3D printing by fostering innovation and research. Some companies replace standard CO₂ laser with new-age fiber laser to make the SLS 3D printer effective in sintering powder more quickly by increasing power density. Likewise, some companies are finetuning SLS 3D printers to reduce material wastage by using one powder as the primary material and another powder as supporting material.

According to Wikipedia, “SLS technology is in wide use at many industries around the world due to its ability to easily make complex geometries with little to no added manufacturing effort. Its most common application is in prototype parts early in the design cycle such as for investment casting patterns, automotive hardware, and wind tunnel models.”

At present, SLS is used commonly by enterprises to facilitate rapid prototyping and production of functional parts. But the SLS 3D printing applications and use cases vary across industries. We can summarize the applications of this additive manufacturing technology based on use cases created by enterprises from various sectors.

Understanding SLS 3D Printing Applications across Industries and Verticals

Manufacturing Industry

One of the key advantages of SLS 3D printing technology is design freedom. Unlike traditional production methods, SLS 3D printing helps engineers to design products with unusual shapes and complex geometries without escalating production time and cost. Manufacturing companies leverage the design freedom to produce moving parts and interlocking parts. Also, this additive manufacturing technology is effective in facilitating small-batch manufacturing.

Aerospace Industry

SLS 3D printers use a flexible, durable, and lightweight material like nylon. Many engineers experiment with various forms of nylon to 3D-print parts tailored for flights and space travels. Also, they opt for SLS 3D printing for projects that require a few items like antennas, drones, aircraft parts, and satellites on demand. NASA has been incorporating 3D printed parts into aircraft engines to curtail both production time and cost.

Automotive Industry

The automotive industry has been using SLS 3D printers to create prototypes as well as produce functional parts. The automotive companies leverage key advantages of SLS 3D printing technology – speed, accuracy, reliability, and durability – to produce end-user components on demand.

Many companies use this additive manufacturing technology to replace obsolete components of vintage cars. 3D scanners make it easier for them to replicate the obsolete components exactly in the form of a digital 3D model. An SLS 3D printer can produce the out-of-stock components physically from the digital files.

Mechanical Industry

Mechanical engineers use SLS 3D printers to create innovative devices, components, and systems by combing principles of physics and mathematics in a variety of ways. Unlike other 3D printing technologies, SLS makes it easier for them to convert out-of-box ideas into components and devices by providing design freedom. Also, the components printed with SLS 3D printers meet varying mechanical requirements through high-dimensional accuracy.

Medical Industry

The medical industry leverages SLS 3D printing to produce complex medical devices accurately and precisely. As mentioned earlier, SLS 3D printers can produce durable and strong items with complex geometries and varying forms. Medical device manufacturers leverage these benefits to produce patient-specific prosthetics and orthotics. They further explore ways to optimize SLS 3D printing technology to fabricate human organs with 100% accuracy and authenticity.

Footwear Industry

SLS reduces 3D printing time by several hours. The reduced printing time makes it easier for footwear companies to produce a variety of insoles according to the varying needs of customers. SLS 3D printing is used widely by footwear companies to produce molded insoles, comfort insoles, and custom orthotics tailored for individual patients. Footwear companies use thermoplastic or nylon as the primary material to print customized insoles that provide support to and ease the pain of patients with flat feet and other foot disorders.

Several market analysis reports forecast the consistent growth of the global SLS 3D printing market over the next few years. Hence, the popularity of SLS 3D printing will remain intact despite the growing popularity of consumer and desktop 3D printing. Enterprises will leverage this mature and reliable additive manufacturing technology by creating new use cases regularly. Also, they will contribute towards evolving SLS 3D printing through research and development (R&D).

About Aurum3D

Aurum3D is one of the leading 3D printing companies in Bangalore. We have been working with various new-age areas like Drone manufacturing and Electric vehicle manufacturers in multiple areas like prototyping and custom 3D printing. You can get in touch with us for your custom requirements in electric vehicle manufacturing.

References:

https://www.shapeways.com/blog/archives/41152-top-applications-for-sls-3d-printing.html

Selective Laser Sintering Applications

You can use a 3D printer to construct a variety of three-dimensional objects physically from digital 3D models. But you can boost the quality and usability of the 3D-printed object only by choosing the appropriate 3D printing technologies. Engineers often opt for selective laser sintering (SLS) as a fast and cost-efficient 3D printing technology. You can further leverage this widely used 3D printing technology to construct items with higher dimensional accuracy and better chemical and mechanical properties.

While planning selective laser sintering applications, you have the option to choose from various production-grade nylon materials in powder form. You can further boost the SLS 3D printing process using 3D nesting software. Enterprises from various sectors use SLS 3D printing technology to print production parts, complex prototypes, innovative tools, and complex parts. They have been extending selective laser sintering applications by creating new use cases regularly.

Varying Selective Laser Sintering Applications and Use Cases

Minimize Material Wastage

Selective laser sintering is often described as a zero-waste 3D printing technology. Unlike other 3D printing technologies, SLS enables engineers to recycle-sintered powdered materials. The non-sintered powdered materials can be recycled after the 3D-printing process without investing in extra time and effort. The new-age SLS 3D printers are built with features to combine new powder and recycles powder seamlessly. That is why; enterprises from various industries opt for selective laser sintering to curtail overall printing costs by reducing both material consumption and material wastage.

Customization and Low-Volume Production

In addition to minimizing material wastage, selective laser sintering is one of the fast 3D printing technologies. Its effectiveness in reducing printing time and cost makes SLS one of the preferred additive manufacturing technologies for low-volume production. Engineers further use an SLS 3D printer to produce customized products and models quickly based on varying customer needs. Enterprises from many sectors facilitate low-volume production and product customization through selective laser sintering applications.

Increase Throughput

SLS enables enterprises to produce customized parts in low-volumes. It further constructs parts and models with no support structures. Hence, enterprises leverage this industrial additive manufacturing technology to deliver a higher number of parts in increasing throughput. The additive manufacturing technology allows engineers to increase throughput without impacting the part’s quality, resolution, accuracy, and surface finish. Many enterprises these days opt for new-age SLS 3D printers to increase throughput and accelerate high-volume production by applying 3D nesting techniques.

Replace Subtractive Manufacturing Methods

SLS is one of the fast and most cost-efficient 3D printing technologies. It enables manufacturers to build production parts, complex prototypes, and end-use components without escalating costs. The manufacturers can further create strong and durable products using a variety of materials. SLS makes it easier for engineers to eliminate the design restrictions associated with conventional production methods. That is why; manufacturing companies find it easier to replace subtractive manufacturing methods with selective laser sintering.

Facilitate Rapid Prototyping

As mentioned earlier, selective laser sintering forms structures by sauntering powder filaments using a high-power laser. The high-power laser beams sinter and blends small powdered grains more efficiently. Hence, it becomes easier for engineers to produce complex prototypes with high precision while experimenting with multiple materials. Also, the engineers can use and evaluate the 3D-printed prototypes immediately after the post-processing stage. Selective laser sintering is currently used widely by manufacturers to add accuracy and precision to the rapid prototyping process.

Produce Heat-Resistant and Chemical-Resistant Parts

SLS facilitates the construction of strong and durable parts using a variety of materials. Engineers also have the option to use 3D printing technology to produce functional parts and tools that can resist both heat and chemicals. They can further produce parts with complex geometries, mechanical joints, or living hinges without increasing printing costs. That is why; SLS is currently used widely by engineers to produce a wide variety of industrial products according to varying process needs.

Create Innovative Tooling

The filaments and materials used in the SLS 3D printing process are effective in enduring a higher amount of stress and absorbing moisture. Also, selective laser sintering helps enterprises to create tools and items that are both strong and durable. That is why; enterprises opt for selective laser sintering to produce a variety of tools, fixtures, and jigs with intricate patterns and complex geometries. Engineers evaluate and fine-tune these complex and innovative tools through rapid prototyping.

Simplify Jewelry Design and Production

While using selective laser sintering, engineers have the option to use metal-based materials like copper polyamide or rapid steel. The support for metal-based materials makes SLS one of the widely used 3D printing technologies in the jewelry industry. Jewelry designers collaborate with 3D artists and engineers to design new jewelry pieces through the direct fabrication of metal designs. Many jewelers further use SLS printers to design personalized and unique pieces of jewelry for their clients.

Keep Medical Treatments Safe

Selective laser sintering is one of the 3D printing technologies that are compatible with commonly used dental materials like thermoplastic, plastic, metal, and ceramic. Also, it produces dental prosthetics with a higher accuracy level. That is why; manufacturers from dental industries opt for this industrial 3D printing technology to fabricate personalized dental prosthetics using ceramic or metal. Dentists have been integrating SLS into their routine practice to perform dental treatments safely. Likewise, physicians use SLS 3D printers to conduct feasibility studies by producing components and prototypes on-demand.

You can opt for SLS 3D printing to construct strong and durable three-dimensional items with high-level accuracy. But you must focus on streamlining the SLS 3D printing process while comparing selective laser sintering applications. Also, you should focus on customizing the printing process by choosing the right SLS 3D printer and the right material.

References:

https://www.3dsystems.com/selective-laser-sintering

https://3digiprints.com/3D-Help/selective-laser-sintering-sls.php

https://www.sciencedirect.com/topics/materials-science/selective-laser-sintering

https://journals.sagepub.com/doi/10.1243/0954405991516912

http://www.cs.cmu.edu/~rapidproto/students.00/jhong/SLS/#materials

https://top3dshop.com/blog/sls-printing-overview#:~:text=The%20SLA%20technology%20is%20used,for%20dental%20and%20surgical%20purposes.

https://www.treatstock.com/guide/article/116-why-every-industy-needs-sls-3d-printing

https://www.hubs.com/knowledge-base/selecting-right-3d-printing-process/#by-use-case