TechnologiesSelective Laser Sintering

SLS — Design Without Constraints

Selective Laser Sintering fuses powdered polymer into solid parts without support structures — unlocking internal geometries, interlocking assemblies, and organic forms that no other additive process can produce as economically. Two materials: PA12 nylon for structural parts, TPU 88A for flexible components.

No Supports

The powder bed itself supports the part during printing. Every internal geometry, undercut, and re-entrant feature is achievable without planning around supports or worrying about their removal.

No Tooling

From a single prototype to a batch of 500 — SLS requires no moulds and no setup costs. Each build can contain multiple different parts, making it highly economical for low-volume production.

Functional

PA12 nylon parts are strong enough for functional testing, assembly trials, and end-use applications directly off the machine. No post-processing required for structural use.

The SLS Difference

What SLS Makes Possible

SLS is the only additive process where the printing medium — a bed of powder — also acts as the support. This fundamental difference changes what is geometrically possible and eliminates the design compromises that support removal imposes on every other process.

Internal channels, cooling passages, and air ducts — printed as single integrated parts, no assembly

Interlocking mechanisms, hinges, and ball joints — printed already assembled

Complex organic surfaces and undercuts — with no support marks to finish

Lattice and honeycomb structures for significant weight reduction

Living hinges and integrated snap-fit features

Multiple different parts nested in a single build — maximising batch efficiency

Design Capabilities

Six Things SLS Does That Other Processes Cannot

Understanding these capabilities is the starting point for designing parts that take full advantage of SLS.

Internal Geometry

Ducts, channels, and hollow cavities that would require multi-part assembly in any other process are produced as single integrated parts. No joints, no sealing, no assembly labour.

Assembled-in-Place

Hinges, sliders, ball joints, and interlocking features can be printed already assembled and functional — with controlled clearances for smooth movement.

Complex Thin Walls

Wall thicknesses down to ~0.8mm with good structural integrity. Ideal for lightweight enclosures, complex shells, and parts where every gram matters.

Lattice Structures

Reduce part weight substantially while maintaining structural performance through integrated lattice or honeycomb infill — a design approach unique to additive manufacturing.

Small Production Runs

10 to 500 parts per batch, without tooling. Mix different parts in a single build. Ideal for pilot production, spare parts programmes, and low-volume end-use supply.

Surface Finishing

Fine matte surface off the machine. Dyeable in a range of colours, paintable, and tumbling capable, for improved aesthetics. Near-production appearance without tooling investment.

SLS Material 01

PA12 — Nylon 12

The benchmark SLS material. PA12 is a tough, slightly flexible engineering nylon with excellent fatigue resistance, long-term dimensional stability, and good chemical resistance. It produces parts with a fine-grained matte surface that is fully functional for structural use.

Property	Value
Tensile strength (X, Y, Z)	50 MPa — isotropic across all build directions
Tensile modulus	1700 MPa
Elongation at break (flat)	16%
Melting temperature	187°C
Chemical resistance	Good — resistant to oils, greases, and many solvents
Surface finish	Fine matte — dyeable and paintable
Support structures	None — powder bed provides all support
Best for	Complex functional parts, ducting, enclosures, living hinges, snap-fits, small production runs

* Values are indicative. Actual properties vary with build orientation and print parameters.

SLS Material 02

TPU 88A — Flexible Polyurethane

Thermoplastic Polyurethane at 88A Shore hardness — A rubber-like SLS elastomer combining high flexibility, abrasion resistance, tear resistance and excellent elasticity. TPU 88A can be stretched, compressed, and repeatedly deformed without permanent damage. It delivers complex geometries impossible to mould, with zero tooling required.

Property	Value
Shore hardness	88A — firm rubber, compressible under load
Tensile strength	8 MPa
Tensile modulus	75 MPa
Elongation at break	270% — highly elastic
Flexural modulus	70 MPa
Impact strength	No break at 23°C
Melt temperature	120–150°C
Hydrolysis resistance	Good — suitable for humid environments
Support structures	None — full design freedom in flexible material
Best for	Seals, gaskets, flexible grips, vibration dampers, overmould prototypes, complex flexible enclosures

* Values are indicative. Actual properties vary with build orientation and print parameters.

Applications

Where SLS Excels

SLS is the preferred process when geometry is complex, volumes are low, and tooling investment is not justified.

Automotive

Air ducts, distribution housings, bracket assemblies with complex internal routing, and under-bonnet components where geometry rules out other processes.

Electronics & EMS

Enclosures with integrated cable routing, complex connector housings, and test fixtures with internal cavities — produced without tooling.

Industrial Equipment

End-of-arm tooling for robots, jigs with integrated clamping features, and production aids where complex geometry directly improves function.

Medical Equipment

Complex housings for diagnostic instruments with integrated mounting features, internal partitions, and access features — as single printed parts.

Low-Volume Production

When you need 20–300 functional parts and tooling cost cannot be justified — SLS delivers end-use quality nylon parts without a mould.

Flexible Components

Seals, gaskets, flexible grips, and vibration dampers in TPU 88A — complex flexible geometries that silicone moulding cannot produce without expensive tooling.

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