PARTS IN 3 TO 5 DAYS
Get High-Quality Laser Sintering (LS) Parts
- Complex Geometries
- High-performance components
- Similar mechanical properties to injection molded parts
Table of Contents
What is Laser Sintering?
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 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.
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 of the parts 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. When 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 does not need support structures.
What are the ideal applications for Laser Sintering?
- Prototypes, form and fit models, architectural models, performance testing, design verification
- Prototypes and end-use parts that have similar mechanical properties to injection-molded parts
- Laser Sintering components in serial batches are more cost-effective than injection-molding
- Complex geometries can be consolidated
- 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 XYZ
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, and Nylon 12
Tolerances:
±.005 in for the first inch and ± .002 in for each additional inch
Layer Thickness:
- EOS: .005 in
- 3D Systems: .004 in
- XYZ: .004 in
Are you ready to get a quote?
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
Glass Beads
Polyamide 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
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
- Biocompatible*
*Special processing may be required. Please notify us of any biocompatibility needs.
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 parts 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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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.
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.
