Laser Sintering

Laser Sintering (LS / SLS) icon

Laser Sintering (LS)—often called Selective Laser Sintering or SLS—creates tough and geometrically intricate components using a high-powered CO2 laser to fuse or sinter powdered thermoplastics. One key advantage of LS 3D Printing is that as a part is made, it remains encased in powder. This eliminates the need for support structures and allows for complex geometries. LS production parts can be strong, water and air-tight, heat resistant, and made out of exceptional materials like aluminum-filled and glass-filled Nylon 12.

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Benefits of LS

Consistency and Repeatability

To ensure consistent build quality, Stratasys Direct Manufacturing has implemented stringent, proprietary process controls and procedures for executing builds, maintaining equipment, and handling materials. We maintain strict parameters for material traceability by monitoring the mixing and testing of powder before builds, tracking the thermal process during the build, and conducting post-process tensile bar testing.

Production Parts

Producing parts for production applications without tooling saves time and money. LS has proven to be an affordable means to build durable, stable production parts in low quantities. It is also effective for high volumes of components when the designs are too complex for traditional manufacturing to execute.

Part Consolidation

Using LS, engineers can incorporate multiple component designs into single structures. With the ability to produce complex features, undercuts, and internal features with ease, LS can consolidate what once was a multi-part assembly into one part. LS can eliminate the need for separate fasteners, mounting components, and adhesives, resulting in substantial weight reduction compared to conventional assemblies.

LS Applications

LS is excellent for functional prototyping or production parts in a variety of taxing environments.

SLS production part
  • Common applications include:
  • Ductwork
  • Fuel tanks
  • Control surfaces
  • Flight-certified parts
  • Brackets, clips, clamps


The New American Muscle Car

Equus Automotive teamed up with Stratasys Direct Manufacturing to aid in the manufacturing of a new iconic American muscle car using Laser Sintering.


Laser Sintering Materials

LS offers a variety of materials and reinforced formulations for lightweight and highly durable parts that can be heat and chemical resistant.


Laser Sintering: Frequently Asked Questions

What geometries are best suited for LS?
LS is ideal for components with extremely complex geometries, including parts with internal cavities. Parts that are produced with LS remain encased in powdered material, which is self-supporting thereby eliminating the need for additional supportive structures on or within the components.
What level of detail can be obtained with LS?
Laser Sintering can produce a layer thickness of 0.004”- 0.006” and an X/Y resolution of 0.030” – 0.050”. We recommend all LS parts have a minimum wall thickness of 0.040”. See the LS design guidelines for more details.
What is the largest part size you can make with LS?
The build platform for our largest LS machine is 26.5”x13.5”x20”. Parts that exceed those dimensions can be built in sections. The mechanical performance of bonded parts is no different than if the component had been created as a single piece.

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