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Selective Laser Sintering (SLS)

1986
  • Carl Deckard
  • Joe Beaman
Selective Laser Sintering machine in an additive manufacturing facility.

Selective Laser Sintering is a powder bed fusion additive manufacturing process. It utilizes a high-power laser to selectively sinter, or fuse, particles of a polymer powder. A roller spreads a thin layer of powder over a build area, the laser scans a cross-section of the part, and the build platform lowers. This process repeats, building the object layer-by-layer.

A key advantage of SLS is that the unsintered powder in the build chamber acts as a natural support for the part being printed. This eliminates the need for separate support structures that must be removed in post-processing, allowing for the creation of highly complex, free-form geometries, including parts-within-parts or interlocking mechanisms printed in a single run. The process takes place in a tightly controlled chamber, heated to just below the polymer’s melting point, which helps to reduce thermal distortion and improve layer fusion. After the build is complete, the entire powder bed and the embedded parts must cool down slowly to prevent warping. The parts are then excavated from the powder bed in a ‘breakout’ process. Unused powder can be collected, sieved, and mixed with fresh powder for subsequent builds, making the process relatively material-efficient. The most common materials are nylons, such as PA11 and PA12, prized for their good mechanical properties. The resulting parts typically have a slightly grainy surface finish but are strong and functional.

UNESCO Nomenclature: 3313
– Industrial technology

Type

Manufacturing Process

Disruption

Substantial

Usage

Widespread Use

Precursors

  • powder metallurgy, the practice of creating objects from metal powders
  • the invention and commercialization of high-power co2 lasers
  • computer numerical control (cnc) systems for precise motion control
  • advances in thermodynamics and heat transfer for process control
  • computer-aided design (cad) software for digital model creation

Applications

  • functional prototypes with robust mechanical properties
  • complex geometries and interlocking parts without dedicated support structures
  • low-to-mid volume production of end-use parts
  • medical device components and orthopedic implants
  • aerospace and automotive ducting and components
  • customized consumer goods

Patents:

  • US 4863538 A

Potential Innovations Ideas

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Related to: selective laser sintering, sls, powder bed fusion, laser sintering, polymer powder, additive manufacturing, carl deckard, nylon, rapid prototyping, support-free.

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Historical Context

(if date is unknown or not relevant, e.g. "fluid mechanics", a rounded estimation of its notable emergence is provided)

Related Invention, Innovation & Technical Principles

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