Parts in 3 to 5 days
High-Quality
Laser Sintering
Parts
- Complex Geometries
- High-Performance Components
- Similar to Injection Molded Parts
Table of Contents
What is Laser Sintering?
Laser Sintering (LS), also known as Selective Laser Sintering (SLS), is an industrial additive manufacturing process that uses powdered thermoplastics (typically nylon) precisely fused by a high-powered laser. The Laser Sintering team can produce the prototypes or parts as fast as one day, cleaned of excess powder, and ready for use or a higher level of finishing.
Additionally, Laser Sintering can create challenging, geometrically complex components. With automated vapor smoothing, these production parts are water-tight, air-tight, heat-resistant, strong, and easy to reproduce. Nylon also can produce living hinges and flexible end-use parts and can be easily dyed in various colors. Industries that take advantage of Laser Sintering are aerospace/defense, automotive, consumer products, and medical/sciences.
How does Laser Sintering work?
Our AM Technicians upload your CAD file, and the software breaks it down layer by layer. In an enclosed chamber heated to just below the powdered material’s melting point, a CO2 laser draws each layer of the part onto the powder bed, fusing the material. When the laser finishes, a roller rolls a new thin layer of powder onto the powder bed, and the process repeats until the parts are complete.
After the build finishes, the whole powder bed is removed and taken to a breakout station where the AM Technicians manually remove each part and brush off the excess powder. Then the components are placed into a container and blasted with a blasting medium to remove any remaining powder. Following this step is complete, the parts go to the finishing department, where they can be sanded, primed, and painted, or we can apply any other finishing techniques we offer.
Note: Laser Sintering or Selective Laser Sintering does not need support structures.
Ideal applications for Laser Sintering
Since Laser Sintering has mechanical properties similar to injection molding, it can produce components in various industries. It’s suitable for parts throughout the product development cycle, from prototypes to end-use components.
Form, Fit, and Concept Models
Architectural Models
Performance Testing
Complex Geometries
Part Consolidation
Jigs and Fixtures
Snap-Fit Joints
Living Hinges
Housings and Enclosures
Laser Sintering at Midwest Prototyping
OEM:
EOS and 3D Systems
Max Build Area:
26 x 13.5 x 21.8 in
Lead Time:
3 – 5 Days
Material:
Fire Retardant Nylon 11, Glass Filled Nylon 12, Nylon 12, and TPU
Tolerances:
±.005 in for the first inch and ± .002 in for each additional inch
Layer Thickness:
- EOS: .005 in
- 3D Systems: .004 in
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Laser Sintering materials at Midwest Prototyping
Material
Description
Key Characteristics
More Information
Fire Retardant Nylon 11 material that meets the FAR 25.853 60-second burn specification.
- White
- Flame Retardant
- Heat Resistant
- Rigid
Glass Filled Nylon 12 is fortified with glass beads. This material creates parts with higher thermal stability and stiffness than regular Nylon 12.
- White
- Chemical Resistant
- Heat Resistant
- High Strength
- Impact Resistant
- Rigid
- UV Stability
Nylon 12 is a robust thermoplastic with exceptional physical properties.
- White
- Chemical Resistant
- Good for Snap Fits
- Heat Resistant
- High Strength
- Impact Resistant
- Rigid
- UV Stability
- Biocompatible*
Ultrasint ® TPU 88A black is a multi-purpose material offering a balanced property profile with good flexibility, shock absorption, and the possibility to print very fine structures with a high level of detail.
- Black (when vapor smoothed)
- Durable
- Elastomeric
- Fatigue Resistant
- Flexible
- High Resolution/High Detail
- UV Stability
*Special processing may be required. Please notify us of any biocompatibility needs.
Compare Materials
Designing parts for Laser Sintering at Midwest Prototyping
Since Laser Sintering or Selective Laser Sintering is a powder-bed-based technology, it does not require support, allowing more design freedom for designers and engineers. The powder is the ‘support’ when designs need complex geometries, interlocking parts, and overhangs. Laser Sintering also allows components to be tightly arranged together to optimize the productivity and speed of the build. The materials we offer have been proven and tested and are high-quality thermoplastics with mechanical properties similar to injection-molded parts with 100% density.
Feature
Measurement
Supported Walls
.028 in
Unsupported Walls
Supports not required
Supports & Overhangs
Supports not required
Embossing & Engraving
Width: .04 in, Height/Depth: .04 in
Horizontal Spans
Supports not required
Holes & Openings
.02 in
Connecting & Moving Parts
Moving: .012 in, Connecting: .006 in
Escape Holes
.04 in
Minimum Features
.03 in
Pin Diameter
.02 in
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Laser Sintering finishing levels at Midwest Prototyping
Level
Process
Description
1
Excess powder removed, and lightly bead blasted.
Standard finish: Parts have visible layer lines and sandstone texture.
2
Excess powder removed, lightly bead blasted, and sealed to lessen porosity.
Sealed finish: Parts have visible layer lines, sandstone texture, and a slight gloss. Parts have a watertight finish.
2 +
Excess powder removed, lightly bead blasted, and cosmetic surfaces sanded to 180 grit.
Functional finish: Removes some layer lines. Parts have a light texture from sanding.
PostPro3D
Excess powder removed, lightly bead blasted, and smoothed using PostPro3D
Automated finish: PostPro3D equipment is used to perform physiochemical smoothing. Smoothed parts have an air-tight, injection-molded-like finish.
3
Sealed, primed, or smoothed with PostPro3D and sanded to 320 grit
Near show quality finish: Removes layer lines. Parts may have minute scratches from sanding and are prime and paint-ready.
Design Tips and Tricks
Living Hinges
How can living hinges benefit your next project? Laser Sintering is one of our in-house technologies that makes living hinges a feasible feature.
