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Selective Laser Sintering (SLS)

General Purpose Prototypes & Production Parts

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.

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. Bio compatibility certifications fulfill requirements for end-use-applications in medical products.

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500k+ 

Parts 3D Printed

± 0.25

MM Part Tolerances

4

Materials

2-5 Day

Average Lead Time

Manufacturing Plastics| 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

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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
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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
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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
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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.

Colours Available: Metallic

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
 
Design Guidelines | Powder Bed Fusion
  • 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

200 x 250 x 330 mm (8 x 10 x 13 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.

Advantages of Powder Bed Fusion

  • Durable

    Create functional parts with consistent durability that are capable of being used in end-use, low-volume production at competitive prices.

  • Production Quantities

    The scability of SLS allows small production runs of end use parts with material properties similar to injection molded parts.

  • Accurate

    Ideal for thin wall parts, SLS is uniquely capable of replicating small features with crisp details and a consistent surface finish.

  • Large Builds

    Produce parts with build volumes up to 22″ x 22″ x 30″ to produce large, complex parts in a single build.

Case Studies | Powder Bed Fusion

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Covid-19 Response

Forge Labs is proud to support the COVID relief efforts, and offers multiple materials suitable for medical-end use applications. The tables below summarize some of the current efforts, applications & materials we are currently providing. This page is routinely being updated as we continue to investigate more applications.

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