SELECTIVE LASER SINTERINGSELECTIVE LASER SINTERING(SLS)(SLS)

SLS HistorySLS History

Selective Laser Sintering was developed by the University Selective Laser Sintering was developed by the University of Texas in 1987.of Texas in 1987.

Commercialized by DTM Corporation, a subsidiary of Commercialized by DTM Corporation, a subsidiary of B.F. Goodrich.B.F. Goodrich.

Company has strong patent to help absorb financial Company has strong patent to help absorb financial burdens of development.burdens of development.

First SLS system shipped in 1992. First SLS system shipped in 1992.

SLS TechnologySLS Technology

• SLS system is ranked as high-end RP SLS system is ranked as high-end RP

modeling.modeling.

• Builds rapid prototyping models using Builds rapid prototyping models using

additive fabrication method.additive fabrication method.

SLS Technology Continued...SLS Technology Continued...

•Click here to view Sinterstation

Pro SLS System and an animated demons

tration on how to use it.

SLS Technology Continued...SLS Technology Continued...

• Uses DTMView software to import, scale, and orient Uses DTMView software to import, scale, and orient part to be modeled. part to be modeled.

• The Sinterstation Pro The Sinterstation Pro is cost-effective. Directly is cost-effective. Directly manufacture customized short production runs.manufacture customized short production runs.

• The Sinterstation Pro has a layer thickness: 0.004" The Sinterstation Pro has a layer thickness: 0.004" or 0.006.“or 0.006.“

• Build size is 22" x 22" x 30." Build size is 22" x 22" x 30." • Tool-less plastic part manufacturing Tool-less plastic part manufacturing • Form/fit/functional plastic prototypesForm/fit/functional plastic prototypes

SLS Technology Continued...SLS Technology Continued...

TYPICAL ROOM LAYOUTTYPICAL ROOM LAYOUTSinterstation Pro SLS system Sinterstation Pro SLS system - Manufactures the part(s) from 3-D CAD data.- Manufactures the part(s) from 3-D CAD data.Rapid Change Module (RCM) Rapid Change Module (RCM) - Build module mounted on wheels for quick and easy transfer between - Build module mounted on wheels for quick and easy transfer between thetheSinterstation, OTS and BOS.Sinterstation, OTS and BOS.Nitrogen Generator Nitrogen Generator - Delivers a continuous supply of nitrogen to the SLS system.- Delivers a continuous supply of nitrogen to the SLS system.Offline Thermal Station (OTS) Offline Thermal Station (OTS) - Pre-heats the RCM before it is loaded into the SLS system and - Pre-heats the RCM before it is loaded into the SLS system and manages the RCMmanages the RCMcool-down process after a build has been completed.cool-down process after a build has been completed.Break Out Station (BOS) Break Out Station (BOS) - In the BOS the parts are removed from the RCM. The non-sintered powder- In the BOS the parts are removed from the RCM. The non-sintered powderautomatically gets sifted and transferred to the IRS.automatically gets sifted and transferred to the IRS.Integrated Recycling Station (IRS) Integrated Recycling Station (IRS) - The IRS automatically mixes recycled & new powder. The mixed - The IRS automatically mixes recycled & new powder. The mixed powder is automatically transferred to the SLS system.powder is automatically transferred to the SLS system.Intelligent Powder Cartridge (IPC) Intelligent Powder Cartridge (IPC) - New powder is loaded into the IRS from a returnable powder - New powder is loaded into the IRS from a returnable powder cartridge.cartridge.When the IPC is connected to the IRS, electronic material information is automatically transferred to the When the IPC is connected to the IRS, electronic material information is automatically transferred to the SLS system.SLS system.

SLS Technology Continued...SLS Technology Continued...

Click here to view the SLS Sinterstation Pro with a typical room layout.

How The Sinterstation Pro Works!How The Sinterstation Pro Works!

First you have to build the setup for the part.First you have to build the setup for the part. Then remove the RCM from the OTS, then placed in the Sinterstation.Then remove the RCM from the OTS, then placed in the Sinterstation. The part is then goes through the Selective Laser SINTERING The part is then goes through the Selective Laser SINTERING

process.process. The RCM is then unloaded from the Sinterstation and placed back on The RCM is then unloaded from the Sinterstation and placed back on

the OTS.the OTS. Then the RCM is then loaded into the BOS, where the part is broke Then the RCM is then loaded into the BOS, where the part is broke

out.out. The used powder is then sifted and transferred to the IRS, new powder The used powder is then sifted and transferred to the IRS, new powder

is then transferred into the IRS.is then transferred into the IRS. The IRS mixes the powders and transfers it back to the SLS System.The IRS mixes the powders and transfers it back to the SLS System.

How SLS (Selective Laser How SLS (Selective Laser Sintering) process works Sintering) process works

How SLS Works :-How SLS Works :- SLS process produces parts directly SLS process produces parts directly from 3D CAD model; layer by layer similar to SLA but from 3D CAD model; layer by layer similar to SLA but rather than liquid resin powder is used. The CO2 Laser rather than liquid resin powder is used. The CO2 Laser provides a concentrated heating beam which is traced over provides a concentrated heating beam which is traced over the tightly compacted layer of fine heat-fusible powder. the tightly compacted layer of fine heat-fusible powder. The temperature in the entire chamber is maintained little The temperature in the entire chamber is maintained little below the melting point of the powder. So laser slightly below the melting point of the powder. So laser slightly raises the temperature to cause sintering, means welding raises the temperature to cause sintering, means welding without melting. For next level, piston moves down along without melting. For next level, piston moves down along with the formed object and powder is spread with a roller with the formed object and powder is spread with a roller for next layer. Process repeats until full object is formed. for next layer. Process repeats until full object is formed.

How SLS (Selective Laser How SLS (Selective Laser Sintering) process works (con’t)Sintering) process works (con’t)

Click here to view a diagram on how the Selective Laser Sintering process works.

SLS UsesSLS Uses

• Produces patterns for casting.Produces patterns for casting.

• Creating highly detailed Functional parts. Creating highly detailed Functional parts.

• Rapid tooling from powdered carbon steel.Rapid tooling from powdered carbon steel.

• Significant impact on prototype manufacturing industry Significant impact on prototype manufacturing industry

and RP job shops.and RP job shops.• Ideal for Automotive, Motorsports, Aerospace, White Goods/Kitchen Ideal for Automotive, Motorsports, Aerospace, White Goods/Kitchen

Appliances, R&D and others needing small to extra-large plastic parts Appliances, R&D and others needing small to extra-large plastic parts from 3-D CAD datafrom 3-D CAD data

SLS Uses Continued…SLS Uses Continued…

•Click here to view samples of SLS uses from the

www.conceptual_reality.com site.

SLS AdvantagesSLS Advantages

• Robust System and High End Products.Robust System and High End Products.

• Conceptual Models.Conceptual Models.

• Functional Prototypes. Functional Prototypes.

• Pattern Masters for casting. Pattern Masters for casting.

• Rapid Tooling.Rapid Tooling.

• Wide Range of Building Materials.Wide Range of Building Materials.

• High Throughput Capability.High Throughput Capability.

• intelligent powder tracking intelligent powder tracking

• Largest available part sizeLargest available part size

SLS DisadvantagesSLS Disadvantages

• Large Amount of Up-Front Capital.Large Amount of Up-Front Capital.

• Designed for Large Manufacturing Industries.Designed for Large Manufacturing Industries.

• High Maintenance CostHigh Maintenance Cost

• High power requirements for Sinterstation Pro.High power requirements for Sinterstation Pro.

• Requires lots of open space.Requires lots of open space.

REFERENCESREFERENCES

• http://http://www.arptech.com.au/slshelp.htmwww.arptech.com.au/slshelp.htm

• http://www.3dsystems.com/products/sls/sinthttp://www.3dsystems.com/products/sls/sint

erstation_pro/index.asperstation_pro/index.asp