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Fast manufacturing with selective laser sintering

Rapid prototyping has long been used as a tool to produce early concept models. Used as visual design aids and initial marketing tools, prototype models were originally limited to the early stages of the design process due to the fragile nature of the materials available. Ongoing research and development within the field of rapid prototyping has led to significant developments in the range of materials available with prototype models now suitable for fit, form and function testing. Taking functionality even further, the selective laser sintering process has proven popular as a tool for the rapid fabrication of production components.

The process

Selective laser sintering is the additive manufacturing process whereby three-dimensional objects are “grown” layer by layer from fused particles of glass, ceramic, plastic or metal. Using an STL file of the required part, a high powered laser selectively draws a cross section of the object onto a thin layer of the SLS material. When the laser hits the powder, it coalesces to create a solid mass that represents a cross section of the part. Once this cross section is complete, the build platform is lowered by 0.1mm and a new layer of dust is spread across the entire build platform. The process is repeated until the final object “grows” layer by layer. Minimal cleaning is required as loose or unsintered material can simply be brushed away to leave the final model.

With minimum cleanup and turnaround times of less than 24 hours offered on the SLS Formiga P100 selective laser sintering machine it integrates seamlessly into the production environment.

Materials

The range of materials available through selective laser sintering continues to increase as research and development of rapid prototyping technologies continues, however some of the more popular SLS materials include.

PA 2200 – a nylon-based material that offers high-temperature resistance and exceptional durability, PA 2200 is suitable for creating live hinges and press-fits.

PA3200GF – the combination of nylon and glass in PA3200 GF produces extremely high temperature resistant components with high stiffness and resistance to mechanical wear.

alumide – Characterized by its high stiffness, metallic appearance, and good post-processing properties, alumide is an aluminum-filled material.

PrimePart UK – a fire-retardant material that offers good dimensional stability.

LOOK – the world’s first high-performance polymer with high temperature, wear and chemical resistance.

PrimeCast: Polystyrene-based PrimeCast offers excellent surface finish and low ash residue, providing an ideal solution for creating lost patterns for micro-casting.

Short production lead times coupled with the range of strong functional SLS materials available help explain the growing popularity of selective laser sintering for low-volume or one-off component production.

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