Ministry of Higher Education and Scientific Research

University of Technology

Department of Production Engineering and Metallurgy

Name: Aya Saleem

Branch: CAD/CAM
Stage: The fourth

Laser Sintering Process

Introduction

Selective laser sintering (SLS) is one of the most rapidly growing rapid
prototyping techniques (RPT). This is mainly due to its suitability to
process almost any material: polymers, metals, ceramics (including
foundry sand) and many types of composites.[1] Principle of Operation
The selective laser sintering (SLS) process is based on the principle that
powder of thermoplastic material , metals, composites or ceramics is
sintered layer by layer, under the heat produced by CO2 laser to build the
part.[2]

Components of Selective Laser Sintering (SLS) System:

1. Pre-processing computer.
2. SLS system computer.
3. Control unit.
4. Optical scanning system.
5. CO2 laser.
6. Powder feed bed.
7. Part build power bed.
8. Powder feed platform and cylinder.
9. Part-build platform and cylinder.
10. Roller mechanism.
11. Process chamber. [2]

Figure1: Selective Laser Sintering Process (SLS). [3]

Working of Selective Laser Sintering (SLS) System :

• The first step in the process is creation of 3D-model.

• The next step is pre-processing which includes :
1- STL file generation.
2- Part orientation.
3- Checking of STL files.
4- Transmission of STL files.
5- Slicing of STL model.

• The real part building process starts with transfer of slice file format
data to rapid prototyping machine by system computer .
• A SLS system consists of powder feed bed containing powdered
polymer (nylon, polyamide, polycarbonate, etc), metals, composite or
ceramics. The powdered polymers (nylon, polyamides, polycarbonate
used in this process are thermoplastic materials.
• The computer controlled optical scanning system redirects the laser
beam. The laser beam scans a layer of powder corresponding to slice
data of 2D cross-section to a depth greater than one layer thickness and
carries out sintering of the powder layer .
• The heat generated by CO2 laser increases the temperature of powder
to a melting point, fusing the powder particles to form a solid layer.
The intensity of laser beam is controlled such that it melts and fuses the
powder only in the area defined by the slicing data.
• After scanning and sintering one layer, the part build platform is
lowered by a depth equal to one layer thickness .
• A roller mechanism convey a new layer of material from powder feed
bed on top of the previously sintered layer for the next scanning and
sintering process.
• The process is repeated until the part is completely built .
• As sintering operation is performed by high power CO2 laser, the build
platform and the powder bed has to be preheated to certain temperature
to avoid part deformation. Therefore, entire setup is kept in sealed and
heated process chamber filled with nitrogen gas. Nitrogen gas prevents
oxidation during sintering process .
• Selective laser sintering process does not require supports. This is due
to the fact that not melted and not fused excess powder in each layer
during process acts as a support .
• After SLS process, the part is removed from process chamber and loose
powder simply falls away .
• The part or prototype is finished by post processing operation such as
sanding, painting etc.[2]

SLS laser :

Different kind of lasers are applied in SLS. Commercial SLS machines

(DTM and EOS) are all equipped with CO2 lasers with maximum
power ratings between 50 and 200 W. The choice of a proper SLS laser
might not be independent of the material to be sintered. Varying SLS
process parameters like laser wavelength ( i.e. type of laser), laser
energy (i.e. power, scan speed and scan spacing) and powder
characteristics (particle size, powder composition, mixing, etc). greatly
influences the resulting part properties such as surface quality or part
density. Optimally, the laser wavelength should be adapred to the
powder material to be sintered, since laser absorption greatly changes
with the material and frequency or wavelength of the laser light.[2]

Advantages of Selective Laser Sintering (SLS) Process:

1. Wide range of materials for parts : The powders of wide range of

materials like : nylon, polyamides, polycarbonates, metals, composites
and ceramics can be used for making parts in selective laser sintering
(SLS) process. This provides flexibility in using materials for parts in
different applications .
2. Capable of producing strong parts : Due to process and type of material
used, selective laser sintering (SLS) process can produce strong and
tough parts. Therefore, functional parts can be built directly.
3. No additional part supports : In selective laser sintering (SLS) process,
the part is supported by not melted and not fused excess powder.
Hence, additional supports are not required. This saves time and
material required for support building.
4. High rate of production : In selective laser sintering process, the parts
can be produced in short time .
5. Minimum post processing required : The parts produced by laser
sintering process require only minimal post-processing such as
sanding .
6. No post curing : The sintered parts produced by selective laser sintering
are fully cured, and hence, does not required further curing. [2]

Limitations of Selective Laser Sintering (SLS) Process :

1. Large physical size of unit : The size of selective laser sintering unit is
large.
2. High running cost : In selective laser sintering process, high power is
required for sintering the powder. In addition, process chamber requires
continuous supply of nitrogen. This increases the running cost .
3. Poor surface finish : There is limitations on the surface finish of the
parts produced by selective laser sintering process due to size of the
powder particles .
4. Generation of toxic gases : Toxic gases are generated during selective
laser sintering process. This leads to pollution. [2]
 Applications of Selective Laser Sintering (SLS) Process :

1. Concept models : The selective laser sintering (SLS) process is used

for making prototypes for concept models .
2. Functional models and working prototypes : The selective laser
sintering (SLS) process is used for making parts that can withstand
limited functional testing .
3. Polycarbonate patterns : The selective laser sintering (SLS) process is
used for making polycarbonate patterns for using in investment casting.
The polycarbonate patterns are suitable for designs with thin walls and
fine features. These patterns are durable and heat resistant .
4. Metal tools (rapid tools) : The selective laser sintering (SLS) process is
used for making tools for low volume production.[2]

Reference :

1- https://www.emerald.com/insight/content/doi/10.1108/0144515031069
8652/full/html
2- https://drive.google.com/drive/u/0/mobile/folders/12dGDCkyZG9mEV
4N7YICJlB-GJoeRpMWO
3- https://www.custompartnet.com/wu/selective-laser-sintering