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

3d Printing Applications In The Electronics Industry

Additive manufacturing or 3D printing has been transforming many industries by driving innovation, accelerating production, and curtailing costs. Electronics is one of the largest global industries that leverage 3D printing technologies to accelerate designing, production, and delivery of a wide range of devices with advanced functionality – computers, televisions, radios, semiconductors, antennas, sensors, and heaters.

Leading consumer electronics companies already use multi-material 3D printers to print electronic devices instead of manufacturing electronic devices. That is why; several market forecast reports suggest a steady growth of the worldwide 3D printed electronics market. According to Datamine Intelligence, “The Global 3D Printed Electronics Market is expected to grow at a CAGR of 39.50% during the forecast period 2021-2028.”

However, most electronic companies use one of the fastest and most accurate 3D printing technologies – material jetting. According to EngineeringProductDesign.com, “Material Jetting (MJ) is one of the 7 types of Additive Manufacturing (AM) technologies in which droplets of build and support materials are selectively jetted onto the build platform and cured by either ultraviolet light or heat to form a 3D object.”

The 3D printing technology accelerates and simplifies the assembling process by producing both functional circuitry as well as enclosures simultaneously. Leading companies have been creating new 3D printing applications in electronics by investing in research and development (R&D). Also, they have been transforming the electronics industry by creating new use cases of multi-material 3D printing in electronics.

Interesting 3D Printing Applications in the Electronics Industry

Creating Design Flexibility

As highlighted by several studies the average lifespan of consumer electronic devices has been decreasing rapidly. Electronic companies have to meet customer expectations by launching lighter and thinner electronic devices with advanced functionality. Unlike conventional production techniques, 3D printing helps engineers focus extensively on a device’s design and functionality.

For instance, engineers cannot produce multilayer circuits using conventional production techniques. But they can use a 3D printer to create multilayer circuits on flexible surfaces by depositing materials in layers. Hence, leading electronic companies to leverage 3D printing technologies to design and launch new electronic devices quickly and frequently.

Customizing Electronic Devices

Like other businesses, electronics companies can boost customer satisfaction and drive sales by launching customized devices instead of standardized devices. The conventional production methods make it difficult for electronics companies to modify or finetune standardized devices. The companies have to incur huge expenditures to deliver customized electronic devices.

But 3D printing technologies create opportunities for electronics companies to deliver customized electronic devices. 3D printers produce physical objects based on digital 3D models. Engineers can make changes to the 3D files according to precise customer instructions without putting in extra time and effort. Also, they can 3D print the customized device to easily reduce the time to market.

Insourcing Prototyping Activities

No company can produce thinner and lighter electronic devices without facilitating rapid prototyping. Often electronics companies outsource prototyping to external companies to overcome constraints related to skills and resources. One of the most important 3D printing applications in electronics is rapid prototyping.

Engineers can use a 3D printer to create and evaluate multiple versions of a prototype quickly and regularly. Hence, many companies leverage 3D printing to curtail procurement costs and eliminate the risk of intellectual property (IP) infringement by insourcing sensitive activity like prototyping.

Producing Non-Standardized Components

Electronics companies cannot produce non-standardized and complex components on-demand using conventional production techniques. But they can produce complex and new components in a few hours using the appropriate 3D printing technology.

Engineers can use a 3D printer to produce components like antennas, sensors, capacitors, printed circuit boards from digital files by depositing filaments in layers. Hence, they can modify the design and functionality of a component according to fresh specifications simply by making changes to the digital 3D models.

Reducing Time to Market

Unlike traditional manufacturing methods, 3D printing does not require engineers to assemble electronic devices. As mentioned earlier, engineers can use material jetting technology to produce both functional circuitry and enclosures simultaneously and precisely. Also, they can produce components and devices by depositing specific materials in layers. That is why; it becomes easier for companies to beat the shortening lifecycle of electronic products by accelerating production and time to market.

Simplifying Supply Chains

The conventional production methods make electronics companies rely hugely on the supply chain model. In addition to maintaining inventory, they have to invest in transportation, tooling, and logistics. Also, they have to explore ways to reduce costs, wastage, and risks by managing the supply chain efficiently.

3D printing technologies enable electronics companies to produce tools, components, and products from three-dimensional digital models. Hence, a company can manufacture the devices and components internally without requiring warehousing and distribution. Also, a company can 3D print electronic devices on demand according to current demands.

Changing and Merging Various Materials

As mentioned earlier, electronics companies facilitate multi-material 3D printing using material jetting technology. However, they use various material jetting technologies to produce parts and components by merging conductive and non-conductive materials.

The 3D printers use solvents to ensure that the conductive and non-conductive materials remain compatible without affecting the component’s functionality. Also, engineers have the option to 3D print components using a wide range of metallic and polymeric inks. At the same time, 3D printing technologies enable engineers to curtail both material consumption and material wastage at a time.

Reducing Upfront and Ongoing Costs

Electronics was one of the early industries that leveraged 3D printers to produce external cases for various devices. Many electronics companies still prefer 3D printing to conventional manufacturing methods to reduce material consumptions. Most electronics companies these days leverage 3D printing technologies to curtail both production time and cost. They replace conventional production methods by 3D-printing various devices and components with customized features.

3D printing is one of the disruptive technologies that have been driving and transforming the electronics industry continuously. The consistent growth of the worldwide 3D printed electronics market depicts the huge impact of additive manufacturing on the industry. At the same time, new use cases created by electronics companies have been boosting the 3D printing applications in electronics consistently.

About Aurum3D

Aurum3D is one of the leading 3D printing service providers in India. Our prestigious clients include many electronics companies. Please feel free to contact us for your custom 3D printing needs.

References:

https://www.datamintelligence.com/research-report/3d-printed-electronics-market

https://amfg.ai/2018/07/03/5-ways-3d-printing-can-transform-electronics/

https://amfg.ai/2019/10/02/application-spotlight-5-electronic-components-that-can-benefit-from-3d-printing/

https://zortrax.com/blog/possibilities-3d-printing-electronics-industry/

https://designwanted.com/design/3d-printed-electronics/

https://www.rapiddirect.com/knowledge-base/article/is-3d-printing-the-future-of-consumer-electronics/

https://www.digitalengineering247.com/article/state-electronic-3d-printing