
Selective Laser Sintering (SLS) 3D Printing Manufacturing
Engineers and manufacturers from a cross-section of industries use selective laser sintering 3D printing (SLS) to create robustly functioning parts. Rapid PSI is proud to offer expert Selective Laser Sintering (SLS) Services – and many other types of Additive Manufacturing as well.
In this article, we will cover:
- What is selective laser sintering 3D printing (SLS)?
- What materials does selective laser sintering 3D printing (SLS) use?
- How does selective laser sintering 3D printing (SLS) work?
- What is selective laser sintering 3D printing (SLS) used for?
- Why you should choose selective laser sintering 3D printing (SLS)
- The benefits of selective laser sintering 3D printing (SLS)
But first, a brief history of selective laser sintering 3D printing (SLS) and where we are now.
A short history of SLS
SLS was a technique created in the mid-1980s by Dr. Joe Beaman and Dr. Carl Deckard.
Their original method has been improved and streamline and can now use the following materials:
- Metals
- Glass
- Ceramics
- Plastics
- Composite material powders
We now collectively categorized these as powder bed fusion. The most common powder bed fusion systems are selective laser melting (SLM) and direct metal laser sintering (DMLS). These are referred to as SLS, selective laser sintering.
In recent years, these processes’ cost has drastically reduced, allowing more industries to benefit from them.
Beaman and Deckard founded one of the first 3D printing startups, called DTM Corp, nine years after creating the process.
The process is streamlined enough that you can find Selective Laser Sintering Services readily available nearly everywhere.

Selective Laser Sintering
- Polyamide 11
- Polyamide 12
- Glass-filled nylon
- Carbon-fiber filled nylon
- Aluminum-filled nylon
- The build is designed, and the powder bin is heated first. They are heating to just below the melting temperature of the polymer.
- A recoating blade spreads a layer of powder over the built form.
- A C02 laser will scan the contour of the following layer. Selectively sintering will occur between the particles of polymer powder.
- A cross-section of the component is scanned; this ensures that the part is solidly built.
- Once that layer is complete, the build platform moves down, and the blade recoats the surface.
- This process is repeated until the part is completed.
- Once the printing is completed, the parts are coated in unsintered powder, and the powder bin will cool down ahead of any part being unpacked.
- The cooling takes around 12 hours to be completed.
- After the cooling period, the part will be cleaned using blasting media or compressed air.
- Automotive hardware
- Wind tunnel models
- Jigs
- Fixtures
- Tooling
- Limited-run manufacturing
- Medical - prosthetics, medical device prototyping, surgical tools
- Military
- Electronic hardware
Selective laser sintering 3D printing (SLS) applications
Here are some examples of SLS technology in use.

Consumer goods
One of the major characteristics that you can expect from our While SLS might sound like it would only be used for tech items, Chanel actually used the technology to create a mascara brush. It is the first and patented mascara brush to be developed using 3D printing technology.

Aerospace
SLS technology is being used for interior parts of aircraft. Emirates has used SLS 3D printing to produce several cabin components, including air vents.

Motorsports
Motorsports teams are competitive, and using innovative materials is an essential part of being ahead of the competition. SLS is used to create aerodynamic wine tunnels, cores, serial parts, and laminating molds.
SLS applications have yet to reach their full potential; however, we are likely to see an increase in it with large brands adopting the technology.

Why you should choose selective laser sintering 3D printing (SLS)
Why you should choose selective laser sintering 3D printing (SLS)
- Labor
- Material
- Equipment ownership
The benefits of selective laser sintering 3D printing (SLS)

Even more significant volumes
Laser sintering machines generally have a bigger print size in comparison to FDM printing options.

Finishing
You can achieve an excellent quality finish when using SLS technology. SLS product parts do not need heavy-post processing. Giving a smooth flat surface and reduced layering effects.

Speed
For short to medium runs, SLS offers a speed that FDM cannot match.

Support parts
You can achieve an excellent quality finish when using SLS
Complex internal cavities, complicated geometric shapes, and overhangs are no issue for SLS printing. Unsintereted powder will act as a support, which saves both money and time.
Post-processing
Selective laser sintering 3D printing doesn’t require curing, soluble baths, or a lot of heavy post-processing.
Once the part is complete, it can be air blasted or sandblasted to produce a high-quality finish.

Full volume
To get the most out of the space and a higher ROI, you can nest your parts. As you will not be printing support parts, you can use the entire volume of space available.

Cost
The combination of not needing to print support parts, the possible nesting, and increased printing speed adds up to a reduced cost per part.

Z strength
Something only possible using SLS printing is the Z-axis mechanical properties.
The evolution of SLS is exciting. Allowing large volume projects with a reduced cost, SLS is regarded as the best option for 3D printing.