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3D printing process – plastics

How works
SLS –
selective laser sintering

Fascination, requirements, fields of application

How does SLS (selective laser sintering) work in detail?

The SLS 3D printer uses a laser as an energy source. This laser selectively melts a powdered plastic material to create a 3D-printed component layer by layer. SLS is a powder-bed-based laser melting process and one of the most advanced and reliable 3D printing technologies in the field of additive manufacturing with plastics.

SLS technology in three steps:

  1. Based on the CAD data, the laser precisely melts the plastic material in the SLS 3D printer at the predefined points.
  2. After the melting process, the build plate lowers and a new layer of powder is added and melted.
  3. This process is repeated layer by layer until the component has been printed in full.

Selective laser sintering is very common in the field of plastic-based additive manufacturing. This is largely due to the superiority of SLS technology in terms of design freedom, high productivity and low unit costs. Unlike other 3D printing technologies such as stereolithography (SLA) or fused deposition modelling (FDM), the SLS 3D printer does not require any additional support structures for component production. As a result, it is able to produce particularly complex, almost impossible 3D printing results. The production of the SLS 3D components only requires powder and energy and no binders.

4 advantages of selective laser sintering

Filled 3D printing materials

SLS can be used to produce high-performance moulded parts for industrial use, e.g. with glass bead fillings, aluminium components or flame-retardant chemicals. Typical requirements include gear wheels, pump impellers or drive wheels for high-pressure systems.

Biocompatibility

It is also possible to manufacture medical devices and patient-specific implants from sterilisable and biocompatible materials. These are more cost-efficient than metal implants.

High-mix & low-volume production

SLS offers a cost-effective alternative for small and medium-sized series production of 3D-printed plastic components. These include, for example, plastic housings or spare parts from the SLS 3D printer.

Function integration

SLS enables the production of 3D-printed components with directly integrated functionality. Plastic components from an SLS 3D printer impress with their lightweight structure and can be produced cost-effectively and customised. These properties make them ideal for use in prototype construction or even for robotic components and gripper systems.

LED design task light in small series

  • The articulated arm table lamp is printed in one piece with fastener and rotation joints. The lamp can be attached to the table and can be rotated in many directions.
  • Small batch |  
  • Polyamide 12 grey |  
  • Depowdering |  
  • Visual inspection |  

Lightweight suction cups

  • Using SLS 3D printing, this lightweight vacuum suction cup with internal air channels can be rethought and manufactured. The filigree grippers lift and move injection-molded parts safely during handling in a pneumatically controlled manner. With the lightweight construction, a 50% weight saving is achieved.
  • Rapid prototyping |  
  • Polyamide 12 |  
  • Depowdering, FKM smooth® |  
  • Visual control |  

Showcase of an intake manifold for V6 pickup engine

  • Made of PA 12 Alumide plastic, the trade fair pattern impresses with its innovative geometry and looks convincingly aluminum-like.
  • Rapid Prototyping / Trade Fair Sample Part |  
  • PA 12 Alumide |  
  • Depowdering, outer surfaces milled over |  
  • Visual control |  

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Your team of contacts
for plastic components

FKM is a pioneer in selective laser sintering (SLS) and selective laser melting (SLM) in Germany and Europe. Since 1994, we have been part of a revolutionary rethinking process in the industry. Where tool and mould making used to determine the design rules, additive manufacturing with SLS and SLM is now changing entire production processes.

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