Laser Sintering Creates Complexity

    What Is Laser Sintering?

    Laser Sintering (LS) is a way to build prototypes early in the design cycle or production parts in a wide variety of applications.

    Laser Sintering (LS), also known as Selective Laser Sintering (SLS), creates tough and geometrically complex components for batch or serial manufacturing in a wide variety of applications.

    LS production parts are strong, water and air-tight, heat resistant and repeatable.

    Prototypes to Production Parts with LS

    This robust process can build parts for all stages of the production lifecycle, from prototyping to low-volume manufacturing opportunities.

    LS builds robust parts with filled Nylon materials, making it an ideal process for applications such as duct work, fuel tanks and brackets, as well as functional prototyping.

    Go Beyond Conventional with Laser Sintering

    With the ability to produce complex features, under cuts and internal structures, LS can consolidate multiple components with ease.

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    Create Complexity with LS

    How Does Laser Sintering Work?

    LS builds with a CO₂ laser that melts cross-sections of a CAD design in powdered material.

    While being built, LS parts remain encased in an unsintered powder bed, replacing the need for support structures.

    Without support structures, designers can easily add undercuts and internal features and reduce post-processing time.

    Laser Sintering Quality Assurance

    Our quality systems ensure consistent handling and recycling of materials along with machine maintenance and process control limits.

    This provides material traceability, mechanical property verification, dimensional and other performance criteria checks to ensure the parts we deliver meet customer specifications repeatedly.

    Engineering-Grade Laser Sintering Materials

    LS provides a full range of engineering-grade thermoplastics well-suited for high requirement applications.


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    Trusted Precision with Laser Sintering

    Laser Sintering Quality Assurance

    Precise LS parts result from more than machine operations; they take a team of experts dedicated to the technology.

    At Stratasys Direct we work to validate all methods and materials in order to ensure perfect parts, every time.

    Years of experience working with LS has led us to develop excellent post-processing methods to offer functional and cosmetic component.

    Laser Sintering Experience in Your Corner

    We have nearly thirty years in the industry and a team of engineers ready to assist with every step of your project.

    With quality certifications ISO 9001 and AS9100 and ITAR registration, we won’t rest until your project requirements are met.


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    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 and bonded.

    Bonding lines introduce a degree of consistency in regards to mechanical performance.


    Download LS Design Guide
    selective laser sintering

    Lead Time Compression

    Bell Helicopter realized a significant lead time compression for their 412 program by employing Laser Sintering to manufacture defog duct nozzles.

    $120K Cost Avoidance

    By using Laser Sintering to manufacture defog duct nozzles for their 412 program, Bell Helicopter estimated a substantial cost avoidance because of the elimination of conventional tooling and rework. 

    Laser Sintering Applications

    selective laser sintering production parts

    Production Parts

    LS production parts can be strong, water and air-tight and made out of engineering-grade thermoplastics. Read More

    selective laser sintering functional prototyping

    Functional Prototyping

    LS is an ideal technology for complex components needed in functional prototyping. Read More

    selective laser sintering ecs ducting

    ECS Ducting

    LS produces strong, complex ducts with interior features using FST-rated materials with superior heat resistance. Read More

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    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.”

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