The Process of SLS in Additive Manufacturing

The Selective Laser Sintering process resembles that of other powder bed fusion technologies in the following ways:

• A designer produces a 3D model using a Computer-Aided Design (CAD) program.
• The design is split into thin (2D) layers.
• The split design is sent to the SLS printer.
• A leveling roller spreads a thin layer of powdered material across the printer’s build platform.
• A CO2 laser traces a cross-section on the material, heating and fusing it together.
• Once a layer is complete, the build platform is lowered to allow space for the next layer of powder.
• Unused material is recycled after each layer is finished.
• The SLS process is repeated, building layer-on-layer until the part is completed.

During the printing process, SLS parts are encompassed by unsintered powder. This extra powder supports the part during printing, removing the need for support structures.

In the process of creating a 3D model, a designer utilizes a Computer-Aided Design (CAD) program to craft the initial design. This design is then segmented into thin, two-dimensional layers. These layers are subsequently transmitted to a Selective Laser Sintering (SLS) printer. At the printer, a leveling roller evenly disperses a fine layer of powdered material across the printer's build platform.

A CO2 laser then follows the contours of each layer, selectively heating and melding the powdered material together based on the cross-section outlined by the designer. Once a layer is fully formed, the build platform descends slightly to accommodate the addition of the next layer of powder. Any surplus material is recycled after each layer. This process iterates, gradually constructing the final object layer-by-layer until the desired part is fully realized.