Laser Sintering (LS)
Laser Sintering (LS), also known as Selective Laser Sintering, is an industrial additive manufacturing process that uses powdered thermoplastics (typically nylon) precisely fused by a high-powered laser. The prototypes or parts can be produced as fast as one day and are cleaned of excess powder and ready for use or a higher level of finishing.
Laser Sintering can be used to create challenging, geometrically complex components for manufacturing. Following 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. Parts made by Laser Sintering can be found in airplanes, automobiles, consumer products, and in the medical and science industries.
Table of Contents
How Does Laser Sintering work?
We input your CAD file into the machine, and the software breaks it down layer by layer. In an enclosed chamber that is heated to just below the powdered material’s melting point, the CO2 laser draws each layer of the part onto the powder bed, fusing the material. When the laser finishes, a roller rolls a new layer of powder onto the powder bed, and the process is repeated until the parts are complete.
After the build is finished, the whole powder bed is removed and taken to a breakout station where the parts are manually removed from the powder, and excess powder brushed off. Then they are placed into a container and blasted with a blasting medium to remove the remaining powder. After this step is complete, they are sent to the finishing department.
Note: Laser Sintering does not need support structures.
What are the ideal applications for Laser Sintering?
- Prototypes and end-use parts that have similar mechanical properties to injection molded parts
- Laser Sintering components in serial batches are more cost-effective compared to injection molding
- It is used to consolidate complex geometries and for complex internal geometries
- It is excellent for parts that need high strength and stiffness, chemical resistance, biocompatibility, and durable functionality
Laser Sintering at Midwest Prototyping
OEM:
EOS, 3D Systems, and Prodways
Max Build Area:
26 x 13.5 x 21.8 in
Lead Time:
3 – 5 Days
Material:
Flame Retardant Nylon 11, Glass Filled Nylon 12, Mineral Filled Nylon 6, Nylon 12
*Most commonly used materials are listed in bold.
Tolerances:
+/- .005 in. for the first inch and +/- .002 in. for each additional inch
Layer Thickness:
- EOS: .005 in
- 3D Systems: .004 in
- Minimum Feature: .02 in
Do you have a question about your design or materials that would fit your project? Email one of our Solutions Managers.
Which Laser Sintering Materials Does Midwest Prototyping Offer?
Material
Description
Key Characteristics
More Information
FR-106
Fire Retardant Nylon 11 material that meets the FAR 25.853 60 second burn specification.
- White
- Flame Retardant
- Heat Resistant
- Rigid
Nylon 12 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
Ultrasint PA6 MF
Ultrasint PA6 MF is a mineral-filled polyamide with excellent tensile strength, stiffness, thermal properties, and chemical resistance.
- Black
- High Strength
- Heat Resistant
PA 2200
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
Compare Materials
Best Practices for Designing Parts for Laser Sintering at Midwest Prototyping.
Since Laser Sintering is a powder-bed-based technology, it does not require supports, allowing more design freedom for designers and engineers. The powder acts as the ‘support’ when designs need features such as complex geometries, interlocking parts, and overhangs. Laser Sintering also allows for parts to be tightly arranged together to optimize the productivity and speed of the build. The materials that we offered have been proven and tested and are high-quality thermoplastics that have 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
What are the 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.
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.
