The world of additive manufacturing or 3D printing is one that uses digital designs and machining processes that create these designs as three-dimensional objects.
It is a cost-effective way to create everything from prototypes to finished parts and has been embraced by businesses, manufacturing companies, hobbyists and scientists around the world.
Within the world of 3D printing, there are lots of different processes that are used. One that has seen exception market growth of late is selective laser sintering or SLS. But what is this and why is it suddenly so popular?
What is selective laser sintering?
SLS uses tiny particles of materials such as plastic, ceramic or glass that are fused together using high powered lasers. This creates a solid three-dimensional object that can be used for many different purposes.
The basic process was developed back in the 1980s by Carl Deckard and Joe Beaman. The pair were involved in one of the first 3D printing companies and would later also be involved with the 3D printing system known as stereolithography.
Their idea built on the basic concept of sintering where objects were created by atomic diffusion. While this might sound complex and modern, it is the same process used to make everything from bricks to porcelain and even jewellery.
SLS in action
Selective laser sintering is a computer-aided design process, so this means that the start of the process is with a computer and a computer file design. It is most common for SLS objects to be printed with powder materials – one common example is nylon which is dispersed in a thin layer on top of the build platform.
Next, the computer-controlled laser tells the object what needs to be printed, tracing a cross-section of the object in the powder on the platform. The laser heats to either sintering or boiling point or above this to melting point to fuse the powder into a solid format.
The platform then drops by a tiny increment, usually around 0.1mm, and the process begins again, building onto the layer already created. This process keeps repeating until the entire object is created then it is left to cool before being taken out of the machine.
What is SLS used for?
As an industry, the use of SLS has seen massive growth in recent times with companies of all sizes coming to realise the benefits of it. But what kind of things is it used for and how might it benefit businesses that don’t traditionally think about 3D printing?
One of the key ways that SLS is used is for industries that only need a small quantity of an object but wants to use high quality materials. Aeroplane parts for the aerospace industry is a great example. Here, it isn’t cost-effective to make physical moulds for aeroplane parts as once made, they are in service for years. But SLS companies can create, redesign or reprint the parts as required.
Another area is customised products ranging from hearing aids to prosthetics and even dental retainers. These don’t need moulds or any additional tooling but can be made to the very specific requirements and individually for each part.
A continued growth industry
More and more companies are realising the benefits of working with experts in selective laser sintering. From creating perfume bottle designs, making parts for washing machines or even things like smartphone cases, there is no end to the range of designs and parts that can be created.
The growth of the industry has already been exceptional and looks set to continue as the range of products and parts created expands and the materials available improve.
