SELECTIVE LASER SINTERING (SLS)

SLS History Selective Laser Sintering was developed by the University of Texas in Selective Laser Sintering was developed by the University of Texas in Commercialized by DTM Corporation, a subsidiary of B.F. Goodrich. Commercialized by DTM Corporation, a subsidiary of B.F. Goodrich. Company has strong patent to help absorb financial burdens of development. Company has strong patent to help absorb financial burdens of development. First SLS system shipped in First SLS system shipped in 1992.

SLS Technology SLS system is ranked as high-end RP modeling. SLS system is ranked as high-end RP modeling. Builds rapid prototyping models using additive fabrication method. Builds rapid prototyping models using additive fabrication method.

SLS Technology Continued... Click here to view Sinterstation Pro SLS System and an animated demonstration on how to use it. Click here to view Sinterstation Pro SLS System and an animated demonstration on how to use it. Click here to view Sinterstation Pro SLS System and an animated demonstration on how to use it. Click here to view Sinterstation Pro SLS System and an animated demonstration on how to use it.

SLS Technology Continued... Uses DTMView software to import, scale, and orient part to be modeled. Uses DTMView software to import, scale, and orient part to be modeled. The Sinterstation Pro is cost-effective. Directly manufacture customized short production runs. The Sinterstation Pro is cost-effective. Directly manufacture customized short production runs. The Sinterstation Pro has a layer thickness: 0.004" or “ The Sinterstation Pro has a layer thickness: 0.004" or “ 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 prototypes Form/fit/functional plastic prototypes

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

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

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 process. The part is then goes through the Selective Laser SINTERING process. The RCM is then unloaded from the Sinterstation and placed back on the OTS. The RCM is then unloaded from the Sinterstation and placed back on the OTS. Then the RCM is then loaded into the BOS, where the part is broke out. Then the RCM is then loaded into the BOS, where the part is broke out. The used powder is then sifted and transferred to the IRS, new powder is then transferred into the IRS. The used powder is then sifted and transferred to the IRS, new powder 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 Sintering) process works How SLS (Selective Laser Sintering) process works How SLS Works :- SLS process produces parts directly from 3D CAD model; layer by layer similar to SLA but rather than liquid resin powder is used. The CO2 Laser provides a concentrated heating beam which is traced over the tightly compacted layer of fine heat-fusible powder. The temperature in the entire chamber is maintained little below the melting point of the powder. So laser slightly raises the temperature to cause sintering, means welding without melting. For next level, piston moves down along with the formed object and powder is spread with a roller for next layer. Process repeats until full object is formed. How SLS Works :- SLS process produces parts directly from 3D CAD model; layer by layer similar to SLA but rather than liquid resin powder is used. The CO2 Laser provides a concentrated heating beam which is traced over the tightly compacted layer of fine heat-fusible powder. The temperature in the entire chamber is maintained little below the melting point of the powder. So laser slightly raises the temperature to cause sintering, means welding without melting. For next level, piston moves down along with the formed object and powder is spread with a roller for next layer. Process repeats until full object is formed.

How SLS (Selective Laser Sintering) process works (con’t) How SLS (Selective Laser Sintering) process works (con’t) Click here to view a diagram on how the Selective Laser Sintering process works. Click here to view a diagram on how the Selective Laser Sintering process works.

SLS 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 and RP job shops. Significant impact on prototype manufacturing industry and RP job shops. Ideal for Automotive, Motorsports, Aerospace, White Goods/Kitchen Appliances, R&D and others needing small to extra-large plastic parts from 3-D CAD data Ideal for Automotive, Motorsports, Aerospace, White Goods/Kitchen Appliances, R&D and others needing small to extra-large plastic parts from 3-D CAD data

SLS Uses Continued… Click here to view samples of SLS uses from the site.Click here to view samples of SLS uses from the site.Click here to view samples of SLS uses from the site.Click here to view samples of SLS uses from the site.

SLS 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 size Largest available part size

SLS 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 Cost High Maintenance Cost High power requirements for Sinterstation Pro. High power requirements for Sinterstation Pro. Requires lots of open space. Requires lots of open space.

REFERENCES erstation_pro/index.asp erstation_pro/index.asp erstation_pro/index.asp erstation_pro/index.asp