What is Selective Laser Sintering (SLS)?

Process: SLS is a rapid prototyping/rapid manufacturing process by which fine, heated powders are melted by a laser to produce fully functional parts. Parts are built with the Vanguard Sinter Station 2500 Plus, which has a build envelope of 12" x 14" x 17". Part tolerances are +/- .003" per inch for prototype runs and can be adjusted for greater accuracy on subsequent manufacturing runs. Most builds are completed within a 1-3 day time period. SLS rapid prototyping helps Excalibur’s clients get their product to market faster than their competitors.

Benefits: SLS parts are built layer by layer and uniquely sintered, not machined or molded. Excalibur’s clients have the freedom to make design adjustments for future runs. Parts can be designed without regard for draft angles or machine restrictions. This makes SLS a perfect candidate for parts with complex geometries and detail. Parts can also be machined or worked after the fact to add threads, holes, or other features. Parts will be manufacturer quality in a fraction of the time and cost. That means less out of pocket costs to develop parts.

Uses: SLS is highly useful in Automotive, Aeronautical, Medical, Outdoor rugged, and enclosure applications. SLS is especially practical for In vivo, Form, Fit, Snap Fit, and Chemical testing (SLS parts are 100% chemical resistant, and can be sterilized with an autoclave). In addition to being excellent for functional prototypes, SLS is one of the only Rapid Prototyping processes that can double as a Rapid Manufacturing Process. Parts will go from Solid Works to production with the click of a mouse.

SLS vs. SLA: Since SLA (stereolithography apparatus) parts will absorb moisture, their material properties are known to degrade over time causing parts to become brittle. SLS parts are traditionally better than SLA parts for their mild to highly aggressive functional testing. SLS parts will uphold their original material properties, from the time they leave the build chamber, this provides a durable, reliable, rugged part.

SLS vs. FDM: SLS and FDM (fused deposition modeling) produce parts with similar accuracy, detail, and surface finish. Unlike SLS, however, FDM is unable to mimic nylon material properties. In addition, FDM is available in ABS plastic, but it does not exhibit the same durability as injection molded ABS and therefore is not reliable to mimic injection molded parts. SLS parts will accurately mimic the strength of injection molded ABS. Finally, speed and cost are also a consideration. SLS is a much faster process and more cost effective where multiple parts are required.

Materials: Excalibur Engineering Services currently builds all parts with 3D System's Duraform PA Nylon. Material specs can be found by visiting www.3dsystems.com.