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What is SLS 3D Printing?

Selective Laser Sintering (SLS) is an advanced additive manufacturing technology that uses a high-powered laser to fuse small particles of polymer powder into a solid structure based on a digital model. The process involves spreading a thin layer of powder onto a build platform, where the laser selectively sinters (or melts) the material according to the CAD design. This is repeated layer by layer until the final part is created. SLS is known for producing highly durable, detailed, and complex components without the need for support structures, making it ideal for functional prototypes, end-use parts, and low-volume production.

SLS Materials

PA12 GF

PA12 GF is a polyamide 12-based technical polymer reinforced with glass fibers. This formulation provides increased rigidity, mechanical strength, and dimensional stability compared to standard PA12, making it suitable for applications that require enhanced resistance and stiffness. Utilizing SLS technology, PA12 GF can produce complex components with precise details and uniform surfaces, ideal for industrial applications requiring high performance and wear resistance.

PA12 GF40

PA12 GF40 for SLS is a material composed of polyamide reinforced with 40% glass fiber. This material provides an optimal combination of mechanical strength, rigidity, and thermal resistance, making it suitable for a wide range of applications. Features include high tensile and flexural strength, good dimensional stability, and improved thermal resistance compared to standard PA12. Typical applications include structural parts, mechanical components, and items subjected to high mechanical stresses.

PA6 GF40

PA6 GF40 is a composite material consisting of polyamide (PA6) reinforced with 40% glass fiber (GF40). This material is particularly well-suited for 3D printing, offering an optimal combination of mechanical strength, rigidity, and dimensional stability. Its properties include high tensile strength, good impact resistance, and increased rigidity compared to standard PA6. Ideal for applications requiring durable and robust parts, such as structural components, gears, and housings.

PA Composite

PA Composite is a polyamide-based reinforced material offering an ideal blend of rigidity, mechanical strength, and high-temperature resistance. It features high specific rigidity and better temperature resistance compared to virgin material and exhibits anisotropic mechanical properties similar to fiber-filled injection-molded materials. Non-conductive and transparent to radio frequencies, it offers a surface that is easy to finish. Typical applications include structural components for UAVs (Unmanned Aerial Vehicles), enclosures, impellers, connectors, and consumer sports equipment.

PA12 HDT

PA12 HDT is a robust polyamide (nylon) polymer characterized by excellent mechanical and thermal properties. Its compatibility with autoclave sterilization, along with good chemical resistance and low moisture absorption, makes it ideal for a wide range of applications. From functional prototypes to final parts, this material provides an optimal balance between mechanical properties and ease of processing, enabling the production of durable and repeatable components without tooling. Applications span aerospace, automotive, medical devices, and consumer sports equipment.

PA12

PA12 is a widely used thermoplastic polymer in SLS technology. It offers a combination of strength, flexibility, and thermal resistance, making it ideal for a broad range of industrial applications, including rapid prototyping, functional component manufacturing, and conceptual modeling.

PA12 Aluminium Filled

PA12 Aluminium Filled is a nylon 12 material loaded with aluminum, providing parts with high rigidity and a metallic appearance. Its excellent surface finish allows for easy machining and polishing for press-fit assemblies or other applications. The material’s mechanical properties make it suitable for consistent, long-term prints, and its high rigidity makes it ideal for rigid functional assemblies. Optimal for housings, automotive parts, and wind tunnel testing requiring a combination of strength, lightness, and metallic aesthetics.

PA12 CF

PA12 CF is a polyamide-based technical polymer filled with carbon fiber, offering exceptional mechanical strength and dimensional stability. Used in sectors such as motorsport, automotive, and medical, it ensures robust and lightweight components. It also features high resistance to deformation and surface resistivity that falls within the ESD safe range, preventing electrostatic charge buildup and making it particularly suitable for electronic applications.

PA12 Flame Retardant

PA12 Flame Retardant is an advanced polyamide 12-based material featuring a halogen-free flame retardant. It is used in 3D SLS printing and is certified JAR 25 for aviation and UL94 V-0 for electronics. It combines elasticity, strength, and surface finish suitable for aerospace, automotive, electronics, and medical applications. Its thermal resistance and self-extinguishing properties make it useful in high-temperature or fire-risk industrial environments.

PP

Polypropylene is a polymer that offers excellent plasticity, elongation, impact absorption, and low moisture absorption, with acid resistance and a density lower than water. Its mechanical properties make it ideal for cost-effective prototypes, parts in contact with liquids, and challenging chemical applications. It is used in automotive, electrical, healthcare, and chemical industries for producing pipes, tanks, prototypes, and chemically resistant containers.

TPU

Thermoplastic polyurethane (TPU) is a material that mimics rubber and is widely used in industry for its flexibility and durability. It is suitable for both prototypes and series production, combining high elongation with outstanding tear resistance. Its properties include resilience, rigidity, good chemical resistance, consistent performance over time, and high-detail resolution. TPU finds applications in various sectors, including automotive, fashion, medical devices, and sports equipment, due to its versatility and adaptability to different conditions.

SLS Material Properties Compared

Material

Colour

Max. dimensions

Tensile Stress at break (MPa)

Tensile Modulus (GPa)

PA12 GF

off-white

550x550x750 mm

26

4,068

PA12 GF

white

680x380x540 mm

57-51

2.5-3.2

PA12 GF40

grey

400x400x540 mm

30

2,55

PA6 GF40

black

400x400x540 mm

73-88

6.5-6.9

PA Composite

white

550x550x750 mm

48-51

5.475-5.725

PA12 HDT

white

550x550x750 mm

43-46

1.586-1.602

PA12

off-white

680x380x540 mm

42-48

1,65

PA12 aluminium filled

metallic grey

300x300x600 mm

48

3.8

PA12 CF

black

680x370x540 mm

85

7,9

PA12 Flame Retardant

white

680x380x540 mm

38-46

2.2-2.5

PP

white

300x300x600 mm

24-29

1.1-1.2

PP

black

N/A

29

1.25-1.30

TPU 86A

black

680x380x540 mm

8

85 MPa

TPU 88A

white

680x380x540 mm

7-8

75 MPa

TPU 70A

white

400x400x540 mm

7

0,065

SLS Surface Finishes

CNC machining

Involves removing excess material from printed parts using computer-controlled cutting tools to meet precise requirements of dimensions and surface finishing.

Dyeing

The process of coloring printed objects using specialized dyes or pigments to enhance their appearance or functionality.

Painting

Involves applying protective coatings or decorative finishes to printed objects using specialized techniques to improve aesthetics and durability.

Vapor Smoothing

Exposing printed plastic parts to solvent vapor to achieve a smooth surface finish by melting and re-solidifying the outer layer reducing porosity and increasing surface finishing

How it works

Our CNC Machining ordering process

Upload your CAD file

Securely upload your CAD file. We guide you step by step.

Receive an instant online CNC Quote

With our instant online CNC quoting tool, you receive a quote for your CNC parts within minutes. We always make sure to offer at least one alternative

Production

We identify the best CNC machining manufacturer and post processor in our network to build your custom CNC parts. Get direct design & technical feedback(review and check)on your CNC parts.

DfM Feedback

We help you optimise your design so you can get the best possible part

Quality control

We validate & certify product functionality according to the required standards.

Receive your parts

Shipment tracking
and necessary
on-time delivery.

Pros & Cons of SLS 3D Printing

Pros

High-quality parts

No support structures required

Allows for complex geometries

Cons

Price: Selective laser sintering machines can be expensive compared to other 3D printing capabilities. 

Rough surface finish

Material waste: Recycling rate is not 100% which can lead to some material waste. 

SLS capabilities compared with other technologies

Capabilities

Max. Dimensions

Min. Feature Size

Min. wall thickness

Tolerance

Description

SLS

680x380x540 mm

0.8mm

0.7-1.3 mm 

±0.3% (±0.3mm)

Uses a laser to fuse powdered materials layer by layer, ideal for creating durable and complex parts without support structures,  widely employed in aerospace, automotive, and medical industries.

DMLS

500x280x340 mm

0.6-0.8 mm

0.22 mm

±0.25 (≤15mm);
±0.5 (>15mm)

Similar to selective laser sintering but uses metal powders, producing high-strength, intricate metal parts suitable for functional prototypes and end-use components in aerospace, medical, and automotive industries.

SLA

1350x750x500 mm

0.2-0.5 mm

1-3 mm

±0.2% (min. 0.2 mm)

Employs a UV laser to cure liquid resin into solid layers, ideal for creating highly detailed, smooth, and intricate parts. Widely used for detailed prototypes and intricate designs in jewelry and dental applications.

MJF

380x284x380 mm

0.5 mm

0.3-0.5 mm

±0.3% (±0.2 mm)

Utilizes multiple jets to apply fusing agents onto powder, which is then fused by heating elements. Delivers high-resolution, functional parts with fast production times, often used in aerospace, automotive, and consumer goods industries.

Polyjet

490x380x200 mm

1.2-2 mm

1 mm

±0.1%

Jetting liquid photopolymer resin and curing it layer by layer with UV light, enabling highly detailed, multi-material parts with diverse properties. Popular in prototyping and complex, color-rich models in medical modeling, consumer goods and electronics fields.

FDM

914x690x914 mm

1.2-1.5 mm

1.5 mm

±0.5% (±0.5 mm)

Uses a heated nozzle to extrude thermoplastic filament layer by layer, ideal for creating durable and functional prototypes. Commonly used in manufacturing, automotive, and consumer products.

DLP

510x280x350 mm

0.5 mm

1 mm

±0.30 mm < 100mm;
±0.3% > 100 mm

Uses a digital light projector to cure liquid resin layer by layer, providing fast and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

Large Scale

2500x2500x4000 mm

3 mm

-

±5 mm/mtl

Uses a digital light projector to cure liquid resin layer by layer, providing fast and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

DED

1200x800x600 mm

-

-

-

Uses an electron beam to melt and deposit metal powders or wire, ideal for repairing or adding features to metal parts in aerospace and manufacturing.

Bindet Jet

430x310x150 mm

-

-

±3% mm

Involves depositing a binder material onto a powder bed to form parts, which are then sintered. Useful for producing complex, cost-effective parts, often used automotive, aerospace, and consumer goods industries as well as jewerky.

FAQ about our SLS 3D Printing service

What are the mechanical properties of SLS 3D printed parts?

SLS 3D printed parts typically exhibit excellent mechanical properties, including high strength, good impact resistance, and durability. The exact properties depend on the material used, but common SLS materials like nylon (PA12) offer strengths comparable to injection-molded parts. The parts are also resistant to wear and chemicals, making them suitable for functional prototypes and end-use applications. The mechanical properties can vary based on the specific material (if reinforced for example) used and post-processing treatments.

What are the dimensional tolerances of SLS parts?

SLS parts typically achieve dimensional tolerances of ±0.3% with a minimum of ±0.3 mm. The accuracy can vary depending on factors such as part geometry, size, and post-processing steps. Smaller and simpler geometries tend to achieve tighter tolerances, while larger and more complex parts may experience slight deviations. For high-precision applications, it is advisable to consult with our team for specific tolerance capabilities.

What are the design constraints for SLS?

SLS offers significant design freedom, but there are still some constraints to consider:
- Minimum Wall Thickness: Generally, walls should be at least 1-2 mm thick to ensure structural integrity, but it is possible to print wall thickness and details small as of 0.8.
- Holes and Channels: Small holes (less than 2 mm in diameter) may not fully form or may require post-processing. Internal channels should have a minimum diameter of 5 mm to ensure proper powder removal.
- Overhangs and Bridges (unsupported features): SLS doesn't require support structures, and can handle overhangs better than some other methods, but large unsupported features may need design consideration to avoid warping or weak spots.
- Interlocking Parts: Allow for sufficient clearance (typically 0.5-0.7 mm) between moving parts to prevent fusing during the sintering process.
- Surface Finish: Parts may have a slightly rough and grainy surface texture due to the nature of the powder-based process. The parts generally have around 6-12 µm Ra (roughness average). While the surface is functional and suitable for many applications, additional post-processing steps can be applied to achieve a smoother finish or specific aesthetic requirements.

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