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Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS)  is the rapid prototyping technology of choice for a range of functional prototype applications, including those with snap fits, living hinges and other mechanical joints. The ability of SLS to produce several pieces at one time also makes the process a good choice for Direct Digital Manufacturing (DDM) of products requiring strength and heat resistance.

Anatomy of the SLS Process

Selective Laser Sintering (SLS) is an additive manufacturing technology developed under sponsorship by the Defense Advanced Research Projects Agency (DARPA) and acquired in 2001 by 3D Systems. The SLS process employs a high power laser to fuse plastic powders layer by layer into  finished prototypes and functional end-use components.

  • Aluminum-Filled (PA12-AL)
  • Carbon Fiber Filled Nylon (Windform XT)
  • Flame Retardant Nylon (Duraform FR100)
  • Glass-Filled Nylon (Duraform GF)
  • Impact-Resistant Nylon (Duraform EX)
  • Nylon (Duraform PA)
  • Rubber-Like (Duraform Flex Plastic)


Rapid Manufacturing

  • Aerospace Hardware
  • UAS, UAV, UUV, UGV Hardware
  • Medical and Healthcare
  • Electronics; Packaging, Connectors
  • Homeland Security
  • Military Hardware

Rapid Prototypes

  • Functional Proof of Concept Prototypes
  • Design Evaluation Models (Form, Fit & Function)
  • Product Performance & Testing
  • Engineering Design Verification
  • Wind-Tunnel Test Models

Tooling and Patterns

  • Rapid Tooling (concept development & bridge tools)
  • Injection Mold Inserts
  • Tooling and Manufacturing Estimating Visual Aid
  • Investment Casting Patterns
  • Jigs and Fixtures
  • Foundry Patterns - Sand Casting


  • Durable, functional parts with high complex geometries
  • Ideal for parts with high heat requirements or chemical resistance
  • Capable of producing parts with mechanical joints, snap fits or living hinges
  • Wide variety of materials and post processing options
  • Short lead times


  • Bead Blasting
  • CA Dip Coated
  • Nickel Plated
  • Painted


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