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Selective Laser Sintering (SLS) 3D Printing

General Purpose Prototypes & Production Parts

Ultra durable, accurate & functional parts with excellent throughput.  Ideal for high volume production.

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What is Selective Laser Sintering?

Selective Laser Sintering (SLS) is an additive manufacturing process that uses powdered thermoplastic polymers. Layers are fused together using a laser that selectively sinters the particles of the powder and binds it together to create a solid structure. SLS offers fantastic throughput with its unique ability to nest thousands of parts within the boundaries of the machine without the need for support structures. 

Parts produced using SLS provide a uniform finish with excellent mechanical properties and abrasion resistance, making it suitable substitute for injection molding as well as functional prototyping alike. Biocompatibility certifications fulfill requirements for end-use-applications in medical products.

SLS 3D printer

26" x 22" 

Max X/Y Build Volume

± 0.25

MM Part Tolerances

4

Materials

2-5 Day

Average Lead Time

Materials| Selective Laser Sintering

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White PA12

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Black PA12

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Glass Filled

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Aluminum Filled

SLS Nylon PA12

Nylon PA 12 (PA2200)

Tough & Durable parts for Prototyping & Production

Nylon PA12 (PA 2200) is a highly functional polyamide material that provides a consistent surface finish,  excellent resolution and feature detail. PA 2200 is ideal for both functional prototyping as well as end use applications that require complex thin wall parts, chemical resistance, snap fits and/or low vibration resistance. PA 2200 is biocompatbile according to EN ISO 10993-1 and USP/Level VI/121 °C

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

50 MPa

ISO 527

Tensile Modulus

1,700 MPa

ISO 527

Elongation at Break

24 %

ASTM D638

Izod Impact Strength

32 kJ/m²

ISO 180

Heat Deflection Temperature

154°C @ 0.65 MPa

ASTM D648

All Details
Material Data Sheet
SLS Black PA12

Black Nylon PA 12

Tough & Durable parts for Prototyping & Production

Black PA12 is a highly functional polyamide material impregnated with black dye to offer a uniform matte black surface finish, along with excellent resolution and feature detail. Black Nylon PA 12 is ideal for both functional prototyping as well as end use applications that require complex thin wall parts, chemical resistance, snap fits and/or low vibration resistance in a black finish.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

50 MPa

ISO 527

Tensile Modulus

1,700 MPa

ISO 527

Elongation at Break

24 %

ASTM D638

Izod Impact Strength

32 kJ/m²

ISO 180

Heat Deflection Temperature

154°C @ 0.65 MPa

ASTM D648

All Details
Material Data Sheet
SLS Glass Filled Nylon

Duraform GF (Glass Filled Nylon)

Stiff Parts for Low Volume Production

Duraform GF is a glass filled polyamide material ideal for creating exceptionally stiff & hard parts for both prototyping and functional end-use applications. Glass Filled Nylon is best for applications that require high heat resistance and dimensional stability. The unique glass filled infill helps prevent warping and breaking making it a great material for creating large functional parts.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

51 MPa

ISO 527

Tensile Modulus

3,200 MPa

ISO 527

Elongation at Break

9%

ISO 527

Izod Impact Strength

35 kJ/m²

ISO 179

Heat Deflection Temperature

179°C @ 0.45 MPa

ISO 75

All Details
Material Data Sheet
Alumide 3D Printing

Alumide

Rigid Metallic Polyamide

Alumide is a unique Selective Laser Sintered polyamide mixed with aluminum particles. Alumide offers a excellent metallic finish with superior thermal properties and dimensional stability. The alumide is a great material for metallic-like parts at low cost.

MEASUREMENT

VALUE

STANDARD

Tensile Strength, Yield

48 MPa

ISO 527

Tensile Modulus

3,800 MPa

ISO 527

Elongation at Break

4%

ISO 527

Izod Impact Strength

29 kJ/m²

ISO 179

Heat Deflection Temperature

179°C @ 0.45 MPa

ISO 75

All Details
Material Data Sheet

Surface Finishes | Selective Laser Sintering

Support structures removed and part is media blasted to offer a uniform finish

Support structures removed and part is deep colour dyed black

 

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Design Guidelines | Powder Bed Fusion

Selective Laser Sintering (SLS) is an additive manufacturing process that uses powdered thermoplastic polymers. Layers are fused together using a laser that selectively scans and hardens the fine particles of powder to create a solid structure. The machine begins sintering at the bottom of the powder bed, building up each cross section by the set layer height of 60-100 um.  Parts produced using SLS provide a uniform finish with excellent mechanical properties and abrasion resistance, making it a suitable substitute for injection molding as well as functional prototyping alike. 

This design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring. We have set minimum allowed tolerances to ensure your parts are built successfully and perform to the the highest standards of the technology.  

Optimizing your designs for Selective Laser Sintering will help keep manufacturing costs down. Price is primarily based upon the X, Y, & Z extents of your part. Small, dense parts are priced the most competitively in this technology. Wall thickness has less of effect on the cost of manufacturing your part than the overall size of it.

Our SLS machines have a building volume of: 700 mm x 380 mm x 580 mm (27.6 x 15 x 22.9 in.), a standard layer thickness of 100 um, and a laser diameter of 0.4mm with a laser offset of 0.25mm. SLS offers excellent part accuracy and repeatability with most parts being within  +/- 0.25mm. Tighter tolerances are achievable upon request.

Forge Labs standard PA2200 Nylon12 white is capable of meeting USP Class VI biocompatibility for end-use-applications in medical devices.

Download Full Design Guidelines
  • Minimum Wall Thickness

    1 mm

  • Engraved Details

    Thickness & depth of at least 0.8 mm

  • Embossed Details

    Thickness & depth of at least 0.7 mm

  • Clearance

    0.5 mm

  • Minimum Hole Size

    1.5 mm or 3 mm for internal chanels

  • Layer Height

    60 μm- 100 μm

  • Maximum Build Size

    700 mm x 380 mm x 580 mm (27.6 x 15 x 22.9 in.)

  • Tolerances

    ±0.25%, with a lower limit of ±0.25 mm.

  • Surface Finish

    Parts are sandblasted and have a uniform grainy matte texture

  • Warping & Deformities

    Avoid large flat planes which are likely to cause warping.

Selective Laser Sintering | Applications

  • Rapid Turnaround

    Whether you need 1 or 1000 parts, get them quickly with Selective Laser Sintering 3D printing.

  • High Accuracy

    Easily produce end-use parts with a uniform finish and excellent aesthetics in a variety of colors.

  • Durable

    Functional parts that are capable of being used in demanding, end-use applications such as aerospace and automotive.

  • Scalable

    The more parts you order, the more efficient and cost effective your parts will be.

Learn How Major Industries Are Using Forge Labs

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Aerospace

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Automotive

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Healthcare

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Practical FX

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Consumer Products

Case Studies | Powder Bed Fusion

 
 

Forge Labs is proud to support the COVID relief efforts, and offers multiple materials suitable for medical-end use applications. 

Read Case Study ->

How Forge Labs used a combination of 3D scanning & SLS 3D printing to reconstruct a 12,500 year old fossilized skeleton of bison occidentalis.

Read Case Study ->