Therefore, it makes complete sense the importance of
prototypes in the manufacturing industry. 3D printing is prominently used for
the making of prototypes, with its rapid and precise ability to create physical
models from digital designs.
Now, when it comes to 3D printing, one of the fastest
growing and most capable technologies used is Selective Laser
Sintering (SLS). In fact, it is considered to be the second most used
technology for 3D printing worldwide.
Wonder what are the reasons behind its popularity? Let’s
explore the benefits of SLS in the 3D printing and manufacturing industry.
What Is Selective Laser Sintering?
It is an additive manufacturing technique for 3D printing
that utilises a high-power laser beam to sinter small particles of polymer
powder into a solid structure based on a 3D model.
The laser beam targeted at the powder melts enough that the
molecules become malleable to join together and create the desired shape. This
method of printing has been broadly classified under the category of Powder Bed
Fusion.
This category involves filling a powder bed with powdered
plastic, metal, glass or ceramic. It is then heated that results in the powder
to adhere to one another.
How Does Selective Laser Sintering Works to Deliver High-Precision 3D
Printing?
This technique works in three key steps to deliver intended
3D printing results. They are —
- Printing:
Inside of the build chamber of a 3D printing system, the powder is
dispersed in a thin layer on top of a platform. The system preheats the
powder to a level below the melting point of the raw material. This way it
becomes easier for the laser beam to raise the temperature of any specific
region of the powder bed as the laser works the process of tracing the
model to solidify a part. Scanning
- the
cross-section of the 3D model, the laser heats the powder to just below or
right at the melting point of the material. It results in mechanically
fusing the particles together and creating one solid part. As for the
unfused powder, it supports the part during printing. The platform is
lowered by one layer into the build chamber, typically between 50 to 200
microns, and the process repeats for each layer until parts are complete.
- Cooling:
After the printing process is done, the build chamber needs to be cooled
down slightly. The cooling is necessary for the inside of the print
enclosure and outside of it. This will help in optimising mechanical
properties of the material and prevent any warping in parts.
- Post-Processing:
Once cooled off, the parts are removed from the build chamber, separated
and then cleaned to get rid of excess powder. The extracted powder can be
recycled and the finished printed parts can undergo further processing
phases of media blasting or media tumbling.
Advantages of Additive Manufacturing — SLS Technique
Now that you know how the SLS technique works for 3D
printing, let's learn about the many perks that this additive manufacturing
technique has to offer.
Quickly Prints Huge Volumes of Parts
One of the highlights of selective laser sintering is that
it has the capacity to produce a huge volume of printed parts. This advanced
technique allows the production team to stack their models tightly inside the
build volume.
An advantage that is not seen in other 3D technologies, even
automatically through a nesting feature, reducing printout times. It is capable
of high throughput at a reduced cost per part in combination with high-speed
laser. Therefore, making them one of the cost-effective
3D printing methods too.
SLS is the ideal option to go for if you are looking for
increased production rates or scaling manufacturing successfully.
Parts Created with High Level of Precision & Flexibility
The accuracy level of the laser beam in SLS technology is
responsible for creating precision parts. As the SLS technique has no
requirement for support structures, the method boasts total flexibility of
form.
Therefore, applications which have a demand for complex
geometries and precise shapes including interior features, undercuts, thin
walls, etc. opt for SLS. Most importantly, if the engineers adhere to the
design specifications, manufacturing complex geometries is easily achievable.
Additionally, selective laser sintering offers intriguing
mechanical benefits that make it possible to create useful components.
Contributes to Functional Prototyping
Selective laser sintering outbids conventional printing
techniques on many levels. One of them is that it creates designs that rely
heavily on particular functionalities.
Support structures are not a need in 3D printing since SLS
uses unfused powder created during the process. This allows for conceiving
features such as moving pieces inside themselves or overhanging structures.
It can also contribute to printing of multiple parts
together as one assembled unit.
No Support Structures Needed
Unlike other additive manufacturing techniques, SLS has no
requirement for support structures. The powder itself works as a
self-supporting element.
During the process, the power is uniformly dispersed into
the build chamber. The unfused powder is used as supports that gives the
advantage of decreasing the need for labour and resource-intensive support
post-processing procedures.
Minimum Wastes Produced During The Process
SLS technique does not involve excessive use of raw material
for prototyping. This means parts can be produced without a lot of wastage of
materials.
In comparison to other processes such as subtractive
manufacturing, SLS is way more efficient. It only utilises powder precisely
needed to create parts to build the final product.
After the parts are finished being printed, the extra powder
can be collected and reused for future production.
3D Printing Metal System with SLS Technology
At Dutco Tennant, we supply high-quality 3D printing metal
machines that utilise SLS technique. Our product is suitable for rapid
prototyping and creating high-resolution nylon parts up faster.
Connect with us to learn about our supplies.
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