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Rapid Prototyping - Selective Laser Sintering (SLS), Rapid Manufacturing, Deposition Machining, Additive Machining
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Selective Laser Sintering (sometimes also known as deposition machining) is a process used to produce prototypes or production parts by selectively melting layers of powdered material together using an accurately controlled laser.
The parts are generated directly from 3D models converted to .stl files which are then sliced into thin layers by the software.
The laser sintering machine produces the parts by building them up on a moveable platform,layer by layer. For each layer, the machine lays down a film of powdered material having an accurate thickness. The laser then melts the selected areas to be formed to the previous layer. The platform then moved down the required layer thickness, a fresh film of powder is laid down, and the next layer is melted by the laser. This continues layer by layer until the parts are complete.
Selective laser sintering can produce parts in a wide variety of materials. Materials include polyimide, glass-filled polyimide, nylon, carbon fiber, tool steel, titanium, stainless steel, bronze, inconel, gold and sand (for ferrous casting cores).
While often considered a rapid prototyping process, one of the real benefits of selective laser sintering is that it can also be used for production parts due to the strength of the material being the same as with traditional processes (up to 99.8% of the density of moulded or machined parts). The plastic processes can be used to produce plastic housings and parts, the metal processes used to produce rapid tooling and complex metal shapes, and the sand process used to produce sand moulds and complex cores.
AN example of using this process for rapid manufacturing is in the production of hearing aid ear shells where each one is customised individually to fit a patients ear. The SLS process enables unlimited variations in design to be produced cost effectively.
Click here to read about applications for direct metal laser sintering for medical applications.
Or click here to read about direct metal laser sintering applicaitons in the tooling industry.
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