Laser sintering is an additive manufacturing (AM) or 3D printing technology that involves using a laser to selectively fuse powdered materials, typically polymers or metals, layer by layer, to create three-dimensional objects. The process is often referred to as selective laser sintering (SLS) and is commonly used in the production of functional prototypes, end-use parts, and complex geometries.
Key features of laser sintering include:
Powder bed: The process starts with a thin layer of powdered material spread evenly over a build platform. Common materials for laser sintering include various polymers, nylon, and certain metal alloys.
Laser sintering: A high-powered laser is precisely directed onto the powder bed to selectively heat and fuse the powdered material based on the cross-sectional pattern of the desired layer. The laser sinters the powder particles, creating a solidified layer.
Layer-by-layer building: After each layer is sintered, a new layer of powder is spread over the previous layer, and the process is repeated. This layer-by-layer approach continues until the entire 3D object is formed.
Cooling and solidification: Once a layer is sintered, the heat quickly dissipates, and the fused material solidifies, forming a bond with the previous layer.
Support structures: In cases where an object has overhanging features, temporary support structures made of the same material are often built alongside the object to prevent deformation during the printing process. These supports can be removed after printing is complete.
Laser sintering is known for its ability to produce parts with complex geometries and functional prototypes with a wide range of material properties. It is widely used in various industries, including aerospace, automotive, healthcare, and consumer goods. The technology has been particularly valuable for producing end-use parts in applications where the strength, durability, and customization of materials are critical.