Laser lines 3d printing

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We visit your premises to understand how you work and recommend the best additive manufacturing solution for your business.

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Create without limits and let ideas become reality.

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Create without limits and let ideas become reality.

Additive manufacturing advice

Browse our informative guides to help you take your next step on your 3D printing journey.

3D printing bureau with unrivalled choice

With direct access to one of the largest 3D printer ranges in Britain, our 3D printing bureau has 18 rapid manufacturing systems on-site.

Working with a comprehensive choice of engineering-grade, batch-traceable thermoplastic materials, our 3D printing service is perfect for producing low volume production parts, jigs, fixtures, cutting and drill guides.

With our 3D printing service, you can save up to 60% in costs in comparison to traditional methods of manufacture.

Case studies

Read some examples of the benefits of additive manufacturing in the real world.

This robotics company relies on the Stratasys F370 3D printer to quickly and cost-effectively produce replacement end-of-arm tools for its network of robots.

Changing to additive manufacturing meant a 90% part reduction and a two minute repair time, rather than 50 minutes.

This digital production facility has a focus on engineering-led solutions and many customers in the automotive, aerospace and medical industries.

With the newest Stratasys machines from Laser Lines featuring SAF and Origin P3 technology, it is staying at the cutting edge.

Testimonials

"The advice we got from Laser Lines was invaluable. The team has a justifiably great reputation and its client confidentiality is second-to-none"

Dave Bennion, Sales and Marketing Director, Ogle Models and Prototypes

"The Laser Lines team was amazingly knowledgeable, helpful, responsive and came back to us ASAP – something that we really appreciated. It couldn’t have gone smoother, and we are so grateful for the support from Laser Lines."

James McInerny, Co-managing Director, Innovate-Design

"I have been impressed at how interested Laser Lines has been in the data and output of the machine and how committed the people there have been in supporting us. This was more than just a sale to them. They are a really nice bunch and a pleasure to work with.”."

Robert Higham, Senior lecturer, NCME

Inspiration

Examples of parts you can produce quickly, accurately and at a low cost using additive manufacturing. Click an image to see a larger version.

• All
• Polyjet
• FDM
• SAF
• Metal
• Origin P3
• SLA

Selective Laser Sintering (SLS) 3D Printing Guide

Selective Laser Sintering (SLS) 3D printing is a technology trusted by engineers and manufacturers across industries to create durable and functional models.

In this detailed guide, we'll explain selective laser sintering technology, the different systems and materials on the market, the workflow and different applications of SLS printers, and when to choose 3D printing with this technology over others. additive and traditional manufacturing methods.

White paper

Looking for a 3D printer to create durable, functional models? Download our white paper to learn how selective laser sintering (SLS) technology works and why it is popular in 3D printing for functional prototypes and end-use products.

Download white paper

Selective laser sintering (SLS) is an additive manufacturing technology that uses a powerful laser to sinter fine polymer powder particles into a solid structure based on a 3D model.

SLS 3D printing has been popular with engineers and manufacturers for decades. With its low model cost, high productivity, and common materials, this technology is well suited for a wide range of applications, from rapid prototyping to low-volume production, limited trial runs, or custom-made products.

Recent advances in technology, materials and software have opened up the possibility of SLS printing to a wider range of companies. Previously, such tools were used only in a few high-tech industries.

Introducing the Fuse 1 high performance SLS 3D printer, finally available.

Webinar

Watch our product demo to learn about Fuse 1 and SLS 3D printing from Formlabs.

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Schematic representation of the selective laser sintering process. The SLS method uses a powerful laser to sinter small particles of polymer powder into a solid structure based on a 3D model.

1. Print: A thin layer of powder is applied to the top of the platform inside the working chamber. The printer preheats the powder to just below the melting point of the feedstock. This allows the laser to more easily raise the temperature of certain areas of the powder bed and monitor the solidification of the model. The laser scans the cross section of the 3D model, heating the powder to the material's melting temperature or just below. Particles are mechanically joined together to form a single solid object. The unsprayed powder supports the model during printing and eliminates the need for special support structures. The platform is then lowered into the working chamber one layer, typically 50-200 µm thick, and the process is repeated for each layer until the models are complete.

2. Cooling down: after printing and before post-processing, the build chamber should cool down a little in the printer body and then outside the body to ensure optimal mechanical properties of the models and avoid their deformation.

3. Postprocessing: finished models must be removed from the working chamber, separated from each other and cleaned of excess powder. The powder can be recycled and printed models can be blasted or tumbled.

To learn more about the workflow, see the SLS 3D Printing Workflow section below.

SLS models have a slightly grainy surface, but the layer lines are almost invisible. To achieve a smooth surface, SLS models are recommended to be blasted or tumbled. This sample was printed on a Fuse 1 industrial 3D printer with SLS technology for workshops from Formlabs.

The green powder supports the model during printing and eliminates the need for special support structures. This makes SLS ideal for complex geometries, including internal features, undercuts, thin walls, and negative draft features.

Models created using SLS 3D printing have excellent mechanical properties: their strength is comparable to that of injection molded models.

Compare Selective Laser Sintering (SLS) 3D printing with other common plastic modeling technologies: Fused Deposition Modeling (FDM) and Stereolithography (SLA).

Selective Laser Sintering (SLS) is one of the first additive manufacturing technologies developed in the mid-1980s by Dr. Carl Deckard and Dr. Joe Beeman at the University of Texas at Austin. Since then, the method has been adapted to work with a variety of materials, including plastics, metals, glass, ceramics, and various powdered composite materials. Today, all of these technologies are classified as wafer synthesis, additive manufacturing processes that selectively sinter regions of a powder layer under the influence of thermal energy.

The two most common substrate synthesis systems currently available are a plastic based method commonly referred to as Selective Laser Sintering (SLS) and a metal based method known as Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM). ). Until recently, both systems were very expensive and complex, which limited their use to the production of small batches of expensive models or custom-made products, such as aerospace components or medical devices.

Innovation in this area will make plastic-based SLS as affordable as other 3D printing technologies such as stereolithography (SLA) and Fused Deposition Modeling (FDM) and become widely available in affordable, compact systems.

All selective laser sintering 3D printers use the process described in the previous section. Basically, such printers differ in the type of laser, the volume of printing and the complexity of the system. Different solutions are used for temperature control, powder dosing and layering in different devices.

Selective laser sintering technology requires high precision and strict control during the printing process. The temperature of the powder and (incomplete) models must be controlled within 2°C during the three stages of production: preheating, sintering and storage before extraction, in order to minimize warping, stress and thermal deformation.

For decades, selective laser sintering has been one of the most popular professional 3D printing technologies, but due to its complexity, strict requirements and high price, only service bureaus and large enterprises could use it.

Conventional industrial SLS 3D printing systems have one or more powerful lasers. An inert atmosphere (nitrogen or other gases) is needed to prevent the powder from oxidizing and breaking down during the printing process, which requires specialized air handling equipment.

These installations also require special heating, ventilation and air conditioning (HVAC) systems and industrial power supplies. In addition, even the smallest industrial installations occupy an area of ​​​​at least 10 square meters. m.

Due to the high initial cost of approximately $100,000 (and much more for complete solutions), traditional industrial systems with SLS technology were out of reach for many enterprises.

As with other 3D printing technologies such as Fused Deposition Modeling (FDM) and Stereolithography (SLA), more affordable, compact systems with SLS technology have recently begun to appear on the market. However, these solutions had significant drawbacks. These include low quality models and complex manual workflows due to a lack of post-processing solutions. This severely limited their use in industrial production.

The Formlabs Fuse 1 printer is in a new category with these deficiencies fixed . It is the first industrial SLS 3D printer for the workshop, delivering high quality, compact size, streamlined workflow, and cost far less than traditional industrial systems of the same type.

The Fuse 1 printer does not require any special infrastructure and will easily fit into your workplace.

The Fuse 1 uses a single laser and has a smaller working chamber that requires less heat. The powder is exposed to elevated temperatures for a shorter period of time, so there is no need for inert gases and specialized ventilation equipment. Thanks to its lower power consumption, it can run on a standard AC power supply without requiring special infrastructure.

The Fuse 1 features patent pending Surface Armor technology. This creates a semi-baked shell that heats evenly around the models as they are printed. This results in excellent surface quality, stable mechanical properties, high reliability and a high material renewal rate.

In addition to providing a compact, self-sustaining ecosystem and complete powder handling capability, Fuse 1 is complemented by the Fuse Sift Station, a stand-alone stand-alone device for model retrieval, recovery, storage and powder mixing.

Overall, the Fuse 1 industrial 3D printer with SLS for workshops has slightly less print volume than traditional entry-level SLS systems, but is smaller, easier to work with and less expensive.

The most common selective laser sintering (SLS) material is nylon. It is a high performance engineering thermoplastic for both functional prototyping and end-use fabrication. Nylon is ideal for the production of complex knots and strong models with high environmental resistance.

3D printed SLS nylon for strength, rigidity and durability. The final models are impact-resistant and highly wear-resistant. Nylon is resistant to UV, light, heat, moisture, solvents, temperature and water. Nylon models printed on a 3D printer are also biocompatible and do not cause allergic reactions. This means that they can be worn and used safely in many situations.

Nylon is ideal for a range of functional applications, from consumer product design to healthcare applications.

Nylon is a synthetic thermoplastic polymer from the polyamide family. It is available in several versions, each designed to print different products. Nylon 12 Powder has a wide range of applications and is a general purpose, general purpose SLS 3D printing powder. Nylon 12 GF Powder is a composite material with a high fiber content, increased stiffness and heat resistance for difficult industrial conditions. Nylon 11 Powder helps fill a gap in prototyping and end-use applications where increased ductility, impact resistance and the ability to withstand wear without brittle fracture are required.

• Impact proof prototypes, fixtures and fittings
• Thin-walled pipes and bodies
• Rivets, fasteners and latches
• Orthopedic products and prostheses*

• High Performance Prototyping
• Small batch production
• One-piece clamping and holding fixtures and tooling
• Conventional SLS models

• Heavy duty clamping and fastening fixtures and spare parts
• Continuous models
• Thread and sockets
• High temperature models

_{* Material properties may vary depending on model design and manufacturing method. It is the manufacturer's responsibility to confirm the suitability of printed models for their intended use.}

109 40% Extension when rupture, Z (%) 6% 3% 907 71 J/m Bending temperature under load at 1. 8 MPa (°C) 87 °C 113 °C 46 °C 170°C 171°C 182 °C

Nylon 12 Powder and Nylon 11 Powder are one-component powders, but some SLS 3D printers can also use two-component powders, such as coated powders or powder blends.

Nylon 12 GF Powder is a composite material with a high fiberglass content, while other nylon composites with aluminide, carbon or glass are designed to increase the strength, stiffness or flexibility of models. In such two-component powders, only the component with the lower glass transition point is sintered, which binds both components.

SLS 3D printing accelerates innovation and helps businesses in a wide range of industries such as engineering, manufacturing and healthcare.

Manage the entire product development process, from iteration of first concept design to production of ready-to-use products:

• Rapid Prototyping
• Product mockups for user feedback
• Functional Prototyping
• Functional testing of products under severe conditions (e. g. piping, brackets)

Manage your supply chain and respond quickly to changing needs:

• End-Use Manufacturing
• Small batch production
• Mass production of new customized consumer products
• Spare parts manufacturing, supply chain sustainability
• Durable, durable clamping and fastening devices (e.g. clamps and clamps) and accessories
• Custom manufacture of automotive, motorcycle and marine equipment parts, and restock military items on demand

Self-manufacturing of ready-to-use medical devices, taking into account the individual characteristics of patients:

• Medical device prototyping
• Prostheses and orthotics (e.g. prosthetic limbs and orthoses)
• Surgical models and instruments
• End use products (nylon 12 biocompatible and sterilizable*)

_{* Material properties may vary depending on model design and production method. It is the manufacturer's responsibility to confirm the suitability of printed models for their intended use.}

Use any CAD software or 3D scan data to design the model and export it to a 3D printable format (STL or OBJ) file. All printers with SLS technology use software that allows you to adjust settings, position models, estimate print times, and layer your digital model. Once set up, the model preparation software sends commands to the printer via a wireless or cable connection.

The Fuse 1 uses PreForm print preparation software (free to download). It allows you to easily duplicate and place multiple models on a 3D grid to maximize your print volume. PreForm automatically suggests the optimal orientation and position of models with the ability to make manual changes.

The workflow for preparing the printer varies from system to system. Most traditional SLS systems require extensive training, tools, and physical actions to prepare and maintain them.

Fuse 1 redefines the SLS workflow, making it simple and efficient, as well as providing trouble-free printing and complete powder handling thanks to modular components.

The Fuse 1 can be easily loaded with powder using a special cartridge.

The Fuse 1 uses a detachable build chamber so you can start a new print while the previous build chamber is still cooling.

Once all pre-checks have been completed, the machine is ready to print. Depending on the size and complexity of the 3D models, as well as their density, printing using SLS technology can take from several hours to several days.

When printing is complete, the build chamber in the housing should cool down a bit before proceeding with the next steps. To start the next print, you can remove the build chamber and insert a new one. Before post-processing, the working chamber must cool down to ensure optimal mechanical properties of the models and avoid their deformation. This can take up to half of the total print time.

Fuse 1 is equipped with a touch screen that allows you to see in real time how each new layer is formed during the printing process. This camera image can also be transferred to a computer using PreForm to monitor the print without leaving the workplace.

Compared to other 3D printing processes, post-processing of SLS-printed models requires a minimum of time and labor. With no supporting structures, it is easy to scale and provides consistent results across batches of models.

After printing is completed, remove the finished models from the build chamber, separate them and clean them of excess powder. As a rule, this is done manually at the cleaning station using compressed air or a jet apparatus.

The excess powder left after the creation of the model is filtered to remove large particles from it. After that, it can be recycled. Under the influence of high temperature, the properties of green powder deteriorate slightly, so for subsequent printing it must be mixed with new material. Due to the possibility of reusing materials, SLS technology produces a minimum amount of waste.

SLS technology typically uses separate devices for powder recovery, storage and mixing. The Fuse 1 workflow uses a single Fuse Sift to retrieve patterns and greens, store, dispense, and mix material streams.

Fuse Sift completes the Fuse 1 SLS print workflow. This system is used for safe and efficient model retrieval and powder recycling.

Fuse Sift automatically doses and mixes used and new powder, reducing waste and controlling powder delivery.

After the powder has been sieved, the 3D models printed using selective laser sintering technology are ready for use. However, there are a few more post-processing steps you can perform on these models.

By default, the surface of 3D models created using SLS technology remains grainy. To achieve a smooth surface, Formlabs recommends blasting or tumbling models made using this method. Models can be spray painted, lacquered, electroplated or otherwise to achieve the desired color, surface quality and properties such as water resistance (special coating) and electrical conductivity (electrolytic coating). Models created with SLS Formlabs are dark in color and therefore not well suited for staining.

Immersion printed SLS model from Partial Hand Solutions.

SLS models can be electroplated for a metal-like surface.

Selective laser sintering is preferred by engineers and manufacturers for its wide design options, high productivity, low model cost and proven end use materials.

Most additive manufacturing processes such as stereolithography (SLA) and Fused Deposition Modeling (FDM) require specialized support structures to fabricate overhang structures.

Selective laser sintering does not require support structures because the unsintered powder surrounds the model during printing. SLS printing makes it easy to create overhangs, intricate geometries, interconnecting parts, internal channels and other intricate details.

Intricately patterned arm splint for weight reduction.

Engineers typically design models in terms of the capabilities of the final manufacturing process, also known as design-for-technology (DFM). When additive manufacturing is only used for prototyping, it comes down to creating models and designs that can be replicated in the manufacturing process using traditional tools.

Selective laser sintering is emerging as a viable rapid production method and its application area continues to expand, so it can open up new possibilities in design and construction. 3D printers with SLS technology can create complex geometries that are impossible or incredibly expensive to manufacture using traditional processes. SLS technology also allows design professionals to combine complex assemblies into a single model that would normally require multiple models to be created. This helps avoid the problem of loose connections and saves assembly time.

Selective laser sintering can unleash the potential of generative design, as it allows the creation of lightweight models that use complex lattice structures that cannot be fabricated by traditional methods.

Selective laser sintering is the fastest additive manufacturing technology for making functional, durable prototypes and end-use products. Lasers used for powder sintering have much faster scanning speeds and are more accurate than the layering methods used in other processes such as Industrial Fused Deposition Modeling (FDM).

To maximize the available print volume in each printer, multiple models can be placed side by side. Operators can use the software to optimize print volume and maximize productivity by leaving only minimal clearance between models.

SLS technology allows operators to fill the build chamber with as many models as possible, as it allows them to be printed without supporting structures, saving time in post-processing.

SLS 3D printing requires the right materials for functionality and versatility. Nylon and its composites are proven, high quality thermoplastic materials. Laser-sintered nylon models have close to 100% density and mechanical properties that are comparable to products made using traditional manufacturing methods such as injection molding.

Screwdriver printed in Nylon 12 Powder. After a simple post-processing, nylon models have a smooth, professional quality surface.

SLS Printable Nylon is an excellent replacement for conventional injection molded plastics. The latches and other mechanical connections produced from it are superior to products created using any other additive manufacturing technology. It is ideal for making functional plastic parts that will work and not break down over time like products created through other additive manufacturing methods.

When calculating the cost of one model, it is usually necessary to take into account the cost of ownership of equipment, material costs and labor costs:

• Equipment cost of ownership: The more models a printer can produce over its lifetime, the lower the cost per model. Therefore, higher performance results in a lower cost of ownership per model. With high laser scanning speeds, the ability to produce multiple models at once to maximize the working volume, and a simple post-processing process, SLS 3D printing guarantees the highest productivity of any additive manufacturing method.

• Material: Most 3D printing technologies use proprietary materials, while nylon is a common thermoplastic that is produced in large quantities for industrial applications. This makes it one of the most inexpensive raw materials for additive manufacturing. SLS 3D printing requires no support structures and allows you to print with recycled powder with minimal waste.

• Labor: Labor is a disadvantage of many 3D printing solutions. Work processes in most technologies are quite laborious and difficult to automate, which can significantly affect the cost of one model. Easy post-processing with SLS printing reduces manual labor and allows for easy scalability.

A 3D printer with SLS technology is a significant investment initially, but this investment often pays off even faster than buying smaller devices. SLS for workshop technology significantly reduces initial acquisition costs and also reduces model costs in most applications.

If 3D printing is rarely used in your business, it is recommended to use the services of third-party service bureaus. But in this case, the cash costs will be higher and you will have to wait longer for the order to be completed. One of the main advantages of 3D printing is its speed compared to traditional production methods. But this advantage loses its value when it takes up to several weeks for a third-party company to deliver a model.

REEKON Tools

Selective laser sintering allows engineers to prototype parts early in the development cycle and then use the same equipment and materials to produce end-use products. SLS 3D printing does not require the same expensive and time-consuming tools as traditional manufacturing, so prototype parts and assemblies can be tested and easily modified in just a few days. As a result, product development time is significantly reduced.

SLS 3D printing is great for creating durable, functional prototypes. They withstand rigorous testing and can be supplied to customers as spare parts or ready-to-use products.

Given the low cost per model and the durability of materials, SLS printing is an economical way to produce complex custom designs or batches of small components for final products.

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