From the Design Lab: An Insider's Guide to Laser Sintering

While all additive manufacturing (AM) processes share the ability to create multifaceted parts with intricate features, each system has its own design guidelines to ensure accuracy and optimize part design for the build process and compatible materials. These design guidelines are usually filed under trade secrets for each manufacturer, which can leave the average design engineer adrift on a sea of 3D printing challenges. To change that, we're sharing our expertise on LS gained from over two decades of working with the technology in a thorough guide.

In our new white paper, we've compiled some of the most important design considerations for any Laser Sintering project, including:
  • Optimal external and internal wall thicknesses based on part orientation
  • Minimum hole diameter based on part orientation
  • Ideal hole proximity to walls
  • Best fonts and font sizes for text
  • How to optimize movable components, like gears and pins
All of these guidelines are validated by test data from the University of Texas at Austin and Stratasys Direct Manufacturing.
selective laser sintering

Download the White Paper

Read An Insider’s Guide to Laser Sintering to take full advantage of this 3D printing process for prototyping and low volume production.

Successful LS Parts at any 3D Printing Experience Level

While all additive manufacturing (AM) processes share the ability to create multifaceted parts with intricate features, each system has its own design guidelines to ensure accuracy and optimize part design for the build process and compatible materials. These design guidelines are usually filed under trade secrets for each manufacturer, which can leave the average design engineer adrift on a sea of 3D printing challenges.

Through years of trial and error, Stratasys Direct Manufacturing has gathered the most efficient design guidelines for one of the most secretive 3D printing technologies: Laser Sintering. This article details a study undertaken by Stratasys Direct Manufacturing and student’s from the University of Texas (UT) at Austin which vetted the tolerances for some of the most challenging LS design features such as minimum wall thickness, optimal build orientation for small to large features, and feature distances and areas in relation to part walls.

Our goal is to make the information collected within the UT study well-known to the average design engineer and present working expectations for what LS can do, and therefore minimize errors and achieve consistently successful LS parts. Download the white paper now to learn more about the currated data. 

Laser Sintering Resources

bell helicopter

Developing Flight-Ready Parts

Bell Helicopter reaps rewards from utilizing LS for ECS components.

Bell needed helicopter parts quickly and with a repeatable processes at a competitive cost with conventional manufacturing. Stratasys Direct finds the answer.

Read Case Study
Key Considerations when 3D Printing with Thermoplastics

Key Considerations when 3D Printing with Thermoplastics

Learn the key differences of 3D printing thermoplastics and related design considerations

Learn the key differences of 3D printing thermoplastics and related design considerations

Read the Article
An Insider’s Guide to Laser Sintering

An Insider’s Guide to Laser Sintering

Discover the most important design considerations for any Laser Sintering project

Read the White Paper
selective laser sintering
How it Works: Laser Sintering

“You can make anything. Any design. Any curves. Any undercuts. Because it’s built in layers, it’s limitless.”