Selective Laser Sintering (SLS) is a high performance industrial 3D printing technology that eliminates the need for support structures while delivering exceptional strength and complex geometries. A high-power laser sinters engineering-grade nylon powder into strong, functional parts. Perfect for functional prototypes and durable end-use parts requiring intricate internal features that traditional manufacturing cannot achieve.
Advanced manufacturing capabilities enable complex geometries, functional prototypes, and end-use production parts that would be impossible or cost-prohibitive with traditional manufacturing methods. From functional prototypes to end-use production parts, this technology delivers exceptional performance across demanding industries.
Support-Free Printing · Complex Geometries
Engineering Applications
Widely used in aerospace, automotive, medical, and consumer products, SLS is ideal for durable, high-performance components with consistent mechanical properties. It supports ESD-safe, temperature-resistant, and USP Class VI biocompatible materials, making it well-suited for engineering and industrial applications. Compared to injection molding, SLS is a cost-effective solution for functional prototypes and low-to-mid-volume production — with fast turnaround times and no need for support structures.
From automotive brackets to medical devices, SLS technology enables complex geometries without support structures, reducing post-processing time and cost. The powder-bed fusion process creates isotropic mechanical properties, ensuring consistent performance across all orientations while maintaining tight tolerances and excellent surface finish.
Complex geometries: Intricate internal channels, overhangs, and assemblies impossible with traditional manufacturing.
Functional prototypes: Test mechanical properties and fit before investing in production tooling.
Custom tooling: Jigs, fixtures, and manufacturing aids tailored to specific production requirements.
End-use parts: Production components for aerospace, medical, automotive, and industrial applications.
Selective Laser Sintering uses a high-powered laser to selectively fuse nylon powder particles layer by layer, creating strong, durable parts without support structures. Unfused powder supports overhangs, enabling complex internal channels and dense nesting in a single build. After cooling, parts are depowdered and finished for consistent mechanical performance.
Step 1 of 4
Fresh nylon powder is loaded and preheated to optimal temperature. The build chamber is filled with nitrogen atmosphere.
Step 2 of 4
Precision recoater spreads thin, uniform powder layers across the build platform with exact dimensional accuracy.
Step 3 of 4
CO₂ laser selectively fuses powder particles layer by layer, creating strong molecular bonds.
Step 4 of 4
Parts cool gradually in powder bed to prevent warpage, then extracted and cleaned via media blasting.
Parts are nested throughout the build volume to maximize batch throughput and efficient powder bed utilization up to 340 x 340 x 600 mm.
Uniform dimensional accuracy across the build with near-isotropic material behavior to ±0.3% (min ±0.3 mm).
Balanced layer thickness for strength and surface finish on functional parts using 60 - 120 microns.
Forge Labs manufactures SLS parts using EOS P 396, EOSINT P 395, EOS FORMIGA P 110 Velocis, Formlabs Fuse 1.
High-performance SLS materials deliver exceptional mechanical, thermal & chemical properties for functional prototyping and low to mid-volume production. Our advanced polymer selection from EOS, Evonik, and Ultrasint offers superior strength, durability, and surface finish quality.
Nylon PA12 is a high-performance engineering thermoplastic that delivers exceptional mechanical strength, chemical resistance, and dimensional stability.
With low moisture absorption and excellent fatigue resistance, it's ideal for both functional prototyping and end-use production parts.
Engineering-Grade Thermoplastic for Production Parts
Compliance
ISO 10993-5 (Cytotoxicity)/ISO 10993-10 (Irritation and sensitization)/EU 10/2011 (Food contact)
Applications
Aerospace Components/Automotive Systems/Medical Devices/Electronic Enclosures
Nylon PA12 ESD combines the proven mechanical properties of our high-performance PA12 material with a specialized electrostatic dissipative coating.
This post-processing treatment provides reliable ESD protection with surface resistance of 1.
Electrostatic Dissipative Nylon with Protective Coating
Compliance
RoHS Directive 2011/65/EU/REACH Regulation (EC) No 1907/2006/UL 94 flammability
Applications
Electronics Manufacturing/Test Equipment Housings/Cleanroom Tools/Production Line Safety
Glass Filled Nylon PA12 (PA 3200 GF) represents a significant advancement in selective laser sintering materials, combining the proven reliability of polyamide 12 with 40% glass bead reinforcement.
This engineered composite delivers exceptional rigidity with a tensile modulus of 3,200 MPa—nearly double that of standard PA12—while maintaining good elongation at break.
Glass Bead Filled PA12 for High-Performance Applications
Compliance
REACH Regulation (EC) 1907/2006
Applications
Automotive Components/Industrial Housings/Wear-Resistant Parts/Forming & Molding Tools
Ultrasint TPU 88A is a thermoplastic polyurethane powder specifically engineered for selective laser sintering applications.
This advanced elastomeric material combines exceptional flexibility with outstanding durability, providing Shore A hardness of 88-90 for optimal balance between softness and structural integrity.
Flexible & Durable Excellence
Compliance
ISO 10993-5 (Cytotoxicity)/OECD 439 (In vitro skin irritation)/ISO 10993-10 (Sensitization)
Applications
Automotive Components/Sports Equipment/Footwear Solutions/Medical Devices
TPU 90A is a rubber-like thermoplastic polyurethane powder for selective laser sintering, and the most flexible material in the Formlabs SLS range.
Parts are 90 Shore A, stretch to 310% along the build plane and resist tearing, so straps, clips, covers and liners flex into place and spring back through daily use.
Skin-Safe SLS Elastomer for Wearables, Grips and Protective Covers
Compliance
ISO 10993-1 (Skin and mucosal membrane contact)/ISO 10993-5 (Cytotoxicity)/ISO 10993-23 (Irritation)
Applications
Orthotics and Prosthetics/Wearables and Straps/Robotics and Automation/Tool Covers and Surface Protection
Engineering-Grade Thermoplastic for Production Parts
Nylon PA12 is a high-performance engineering thermoplastic that delivers exceptional mechanical strength, chemical resistance, and dimensional stability. With low moisture absorption and excellent fatigue resistance, it's ideal for both functional prototyping and end-use production parts.
Tensile Strength
50 MPa
Flexural Modulus
1500 MPa
Temp Resistance
157 / 145 °C
Compliance
ISO 10993-5 (Cytotoxicity)/ISO 10993-10 (Irritation and sensitization)/EU 10/2011 (Food contact)
Applications
Aerospace Components/Automotive Systems/Medical Devices/Electronic Enclosures
Electrostatic Dissipative Nylon with Protective Coating
Nylon PA12 ESD combines the proven mechanical properties of our high-performance PA12 material with a specialized electrostatic dissipative coating. This post-processing treatment provides reliable ESD protection with surface resistance of 1.
Tensile Strength
50 MPa
Flexural Modulus
1500 MPa
Temp Resistance
157 / 145 °C
Compliance
RoHS Directive 2011/65/EU/REACH Regulation (EC) No 1907/2006/UL 94 flammability
Applications
Electronics Manufacturing/Test Equipment Housings/Cleanroom Tools/Production Line Safety
Glass Bead Filled PA12 for High-Performance Applications
Glass Filled Nylon PA12 (PA 3200 GF) represents a significant advancement in selective laser sintering materials, combining the proven reliability of polyamide 12 with 40% glass bead reinforcement. This engineered composite delivers exceptional rigidity with a tensile modulus of 3,200 MPa—nearly double that of standard PA12—while maintaining good elongation at break.
Tensile Strength
51 MPa
Flexural Modulus
2900 MPa
Temp Resistance
157 °C
Compliance
REACH Regulation (EC) 1907/2006
Applications
Automotive Components/Industrial Housings/Wear-Resistant Parts/Forming & Molding Tools
Flexible & Durable Excellence
Ultrasint TPU 88A is a thermoplastic polyurethane powder specifically engineered for selective laser sintering applications. This advanced elastomeric material combines exceptional flexibility with outstanding durability, providing Shore A hardness of 88-90 for optimal balance between softness and structural integrity.
Tensile Strength
8 MPa
Flexural Modulus
70 MPa
Temp Resistance
See datasheet
Compliance
ISO 10993-5 (Cytotoxicity)/OECD 439 (In vitro skin irritation)/ISO 10993-10 (Sensitization)
Applications
Automotive Components/Sports Equipment/Footwear Solutions/Medical Devices
Skin-Safe SLS Elastomer for Wearables, Grips and Protective Covers
TPU 90A is a rubber-like thermoplastic polyurethane powder for selective laser sintering, and the most flexible material in the Formlabs SLS range. Parts are 90 Shore A, stretch to 310% along the build plane and resist tearing, so straps, clips, covers and liners flex into place and spring back through daily use.
Tensile Strength
8.7 MPa
Flexural Modulus
See datasheet
Temp Resistance
See datasheet
Compliance
ISO 10993-1 (Skin and mucosal membrane contact)/ISO 10993-5 (Cytotoxicity)/ISO 10993-23 (Irritation)
Applications
Orthotics and Prosthetics/Wearables and Straps/Robotics and Automation/Tool Covers and Surface Protection
SLS parts feature a fine-textured matte surface finish that is durable and functional, making them ideal for a wide range of applications. While the natural finish is suitable for many uses, SLS parts can be further enhanced through post-processing techniques. Deep color dyeing with DyeMansion technology provides vibrant, uniform colors, while painting allows for a smooth, professional finish that can match precise aesthetic requirements.
Selective Laser Sintered (SLS) parts naturally come in a fine-textured matte surface finish. Parts are depowdered through media blasting, resulting in a bright white color with a slightly grainy texture. The surface is durable, uniform, and functional, making it ideal for both mechanical and aesthetic applications. While intricate details are well-defined, the porous nature of SLS PA12 can lead to a slightly rough feel, which can be improved through post-processing techniques.
Finish attributes
Deep color dying provides a rich, uniform color, improving the overall aesthetics. Suitable for both functional and visually appealing applications. The dye also enhances scratch resistance, making the parts more durable in handling and use. This process ensures consistent color uniformity across the entire part, even for complex geometries or intricate designs.
Finish attributes
Vapour finishing uses controlled chemical vapour to smooth the surface texture of SLS parts, reducing the characteristic powder grain while maintaining dimensional accuracy. This process creates a more refined surface feel and appearance, making it ideal for parts requiring improved aesthetics or user interaction. The result is a smoother touch feel while preserving the structural integrity and detail definition of the original part.
Finish attributes
Painting offers a highly durable, automotive-grade coating that enhances the aesthetics and durability of 3D-printed parts. Each part is hand-finished to ensure smooth surfaces and a premium quality appearance. Using professional-grade coating equipment, this process allows for precise application and exceptional adhesion. Custom color matching is available, making it ideal for applications that require specific branding or visual impact.
Finish attributes
Support-free builds move faster when finishing, inserts, and quality controls are planned at the quoting stage.
Insert and thread integration
Heat-set inserts, tapping, and hardware prep for direct assembly.
Nesting and batch planning
Pack strategies that balance throughput, cooling behavior, and part quality.
Dimensional control checks
Tolerance sampling and first-article verification before scaled production.
Our Selective Laser Sintering (SLS) design guidelines help engineers and designers improve part quality, lower costs, and speed up production. This section is a quick primer before full DFM review.
Maximum Build Volume
340 x 340 x 600 mm (13.4 x 13.4 x 23.6 in)
Our EOS SLS machines (EOS P396 and EOS P110 Velocis) offer a maximum build volume of 340 x 340 x 600 mm (13.
General Tolerances
Nylon PA 12: ±0.3% (min ±0.3 mm)
Typical tolerances for SLS Nylon 12 parts are ±0.
Minimum Wall Thickness
0.8 mm - 1.0 mm (0.031" - 0.039")
Supported walls, which are connected on at least two sides and thick enough to support the model, require a minimum thickness of 0.
Layer Height
60 - 120 Microns
The layer height is the overall Z resolution of the part; we avoid stepping artifacts on important features of your models by orienting the part(s) along the Z plane or at a 20 degree angle on all sides.
SLS uses a laser to fuse nylon powder layer by layer, creating strong parts without support structures. This enables complex internal geometries impossible with traditional manufacturing, while batch production keeps costs low for small to medium runs.
Upload files, configure manufacturing specs, and track production in one workflow built for engineering teams.
75% complete
Step 01
Automated file checks before production
Drop your CAD files and receive immediate manufacturability feedback. Critical geometry and wall checks run as soon as files are uploaded.
Selective Laser Sintering (SLS) is used for durable nylon parts that need real mechanical performance. Support-free printing enables complex internal features, dense batch production, and end-use components that would be difficult or costly to tool.
SLS is a strong fit for functional prototypes and production parts that must survive handling, impact, and repeated use. It is often used to consolidate assemblies, reduce part count, and ship nylon components with consistent properties across builds.
Lightweight functional components for aerospace assemblies.
Example parts
Lightweight ducting, brackets, UAV structures, and topology-optimized housings.
Why it fits: SLS enables topology-optimized geometries with complex internal channels and overhangs — no support structures limit part design, reducing weight while maintaining structural integrity.
High-detail architectural models and urban planning prototypes.
Example parts
Massing models, site context blocks, and presentation-ready assemblies.
Why it fits: SLS produces durable, matte-finish models that withstand frequent handling and transport, with dense nesting to batch dozens of building components in a single build.
Functional prototypes and lightweight vehicle components.
Example parts
Intake ducting, brackets, cabin clips, and under-hood test components.
Why it fits: SLS allows rapid iteration of functional parts with nylon materials rated for under-hood temperatures, without committing to tooling before design lock.
Highlighted Case Study
Aerospace manufacturing
Aerospace teams used SLS and DMLS to redesign critical components with topology-optimized geometry, reducing mass while maintaining structural performance and certification readiness.
• 40-60% weight reduction strategies
• Complex internal geometries
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STEP, STL, OBJ, 3MF and IGES supported
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