SRI VENKATESWARA COLLEGE OF

ENGINEERING AND TECHNOLOGY

NH-5, Etcherla, srikakulam, Andhra pradesh-532410

Accredited by NAAC with Grade “A”

Approved by AICTE, Affiliated to JNTU Kakinada

A SEMINAR REPORT ON

SELECTIVE LASER SINTERING MACHINE

Under the esteemed guidance of

Mr.L. Mohana rao M.tech

Assistant professor

Department of Mechanical Engineering

Seminar report is Submitted by

Bonumaddhi Ramakrishna
 19MT5A0308

CERTIFICATE

This is certify that the seminar report on “SELECTIVE LASER

SINTERING MACHINE” is being submitted by BONUMADDHI RAMA
KRISHNA (19MT5A0308) is an authentic work that has been carried out by
him under my supervision and guidence of Mr.L.MOHANA RAO, M.tech, is
submitted partial fulfillment for the requirements for the award of Bachelor
of technology in DEPARTMENT OF MECHANICAL ENGINEERING at sri
Venkateswara College of Engineering and Technology during the academic
year 2019-2022.

Project Guide Head of the Department

Mr.L.MOHANA RAO M.tech Dr.N.MAHESH KUMAR

M.tech,phD
Assistant professor Associate professor

CONTENTS

CHAPTER PAGE
NO

1.ABSTRACT 5-6

2.INTRODUCTION
7

2.1.Working principle
8

2.2.Working process 9-
11

2.3.Models 12

2.4.Specifications 13-
14

2.5.Components
15

2.6.Materials
15

2.7.Advantages
16

2.8.Disadvantages
16
3.LITERATURE REVIEW 17-
18

4.METHADOLOGY
19

5.CONCLUSION
20

6.REFERENCES 21-
22

DIAGRAMS COLLECTION

Sl.No DIAGRAM PAGE

NO

1. 2.2.1.Construction of SLS Machine 10

2. 2.2.2.Working process of SLS Machine 12
3. 4.1 Methodology of SLS Machine 19
 LIST OF TABLES

Sl. No PAGE NO

1. Specifications of sinterstation HIQ series 14

2. Specifications of sinterstation HIQ+HS series 15

CHAPTER-1

ABSTRACT

Selective laser sintering (SLS) is a highly flexible rapid prototyping

(RP) technology which can use a wide range of powdered materials to
generate high quality complex geometries directly from digital models. The
SLS process uses a laser to sinter selected areas of powdered materials to
produce solid objects layer by layer, according to the 2D data obtained from
CT scan or MRI imaging techniques.

This article presents a comprehensive literature review of biomedical and

clinical applications of selective laser sintering (SLS) with a focus on polymer
and composite powders. A brief review of the SLS process is provided,
followed by optimal material processing conditions and recent progress with
in material development research.

The latest best practices for biomedical applications of SLS are elaborately
discussed by means of case studies, focus in on patient-specific guides and
prosthetics, pre-surgical planning, and bone scaffolds for tissue engineering. It
is shown that SLS has been widely used as an additive manufacturing
technique rather than only a rapid prototyping technology in spite of the
limited number of applicable polymers currently present. The investigations
carried out so far, suggest that SLS can greatly contribute to the clinical and
biomedical fields by increasing accuracy along with reducing cost and time in
the long-run.
Keywords: Selective laser sintering (SLS), Powder-based additive
manufacturing, Rapid prototyping (RP) technology, 3D printing, , surgical
planning, T issue engineering scaffolds, patient -specific implants, prosthetics
 CHAPTER-2

INTRODUCTION

Selective Laser Sintering has grown to be one of the world’s most

promising rapid prototyping methods in use over the past several decades.
The technology was developed at the University of Texas at Austin by Carl
Deckard and Joseph Beaman.
 The process was then commercialized by two companies, DTM Corporation60
and EOS GmbH Electro Optical System The SLS patents were the highest
revenue generating intellectual property of UT Austin for many years. Desk
Top Manufacturing (DTM) Corp. (Austin TX) used to offer this powder-based
system which was acquired by 3D Systems in 2001. First commercial machines
were shipped in December 1992.

The second commercial system for laser-sintering was launched by EOS

GmbH of Munich, Germany, first shipped in April 1994. Both of these systems
and their successor models became very successful commercial machines, each
having sold many hundreds until today, and led to the introduction of metal
processes. DTM was subsequently acquired by 3DSystems in 2001.

2.1 WORKING PRINCIPLE

Selective laser sintering is a leading-edge rapid prototyping and additive

manufacturing technology that can generate finished quality parts directly from
computer-aided design (CAD) models or stereolithography (STL) files of an object,
thus saving significant amount of time and expense.

It provides the capability to create complex and organic geometries not possible
through other manufacturing techniques. This paper will review a wide array of
the latest trends in additive manufacturing and rapid prototyping as they relate to
clinical medical practice and related engineering fields using the selective laser
sintering production technology.

The topics of patient-specific guides and prosthetics, pre-surgical planning

models, and bone scaffolds for tissue engineering will be highlighted with attention
to the material development and special production considerations, advantages,
and disadvantages of selective laser sintering. In addition this paper will explore
thebrief history of SLS technology along with a detailed discussion on the process
and current commercial machines used to date.

2.2 WORKING PROCESS

Using 3D CAD data of the component, three dimensional prototype is produced by

solidification of materials powder by layer by layer. Heat produced by CO2 laser,
scanning system and roller mechanism. Heat fusible type materials powder is used
as initial material input to the machine.
SLS process occurs in three stages, which include preprocessing, component
development and post processing.

Fig 2.2.1: CONSTRUCTION OF SLS

STAGE -1:

PREPROCESSING:
 Initially, CAD model in STL file format is loaded into the SLS
machine. System software cuts the model into number of horizontal slices. It also generates the
cross-sectional data of each Slice for laser scanning.

STAGE-2:

COMPONENT DEVELOPMENT:

In this stage, powdered material is allowed to get

deposited over the work plate, to a predetermined height. Scanning system directs the laser be
from the CO2

Laser on to the powdered material on the base plate. Laser beam scans the power surface so
that only cross-section of the bottom most slice of CAD model gets fused. Remaining portion of
powder on the work plate does not undergo solidification by fusion.By the end of scanning
operation, first sintered layer is formed, with solidified cross section representing bottom most
slice and powder surrounding the solid cross-section acts as support for next layer.

Over the first sintered layer, another layer of powder is deposited using roller mechanism. This
powder layer gets scanned by laser to obtain sintered layer with cross-section of immediate
bottom most slice of the model. Process repeats until all the layers equal to number of slices of
model are developed.

STAGE-3

POST PROCESSING:
On completion of all layers, stack of sintered layers or sintered component is lifted
from the work plate. During, lifting only the component gets extracted and
supporting material i.e., powder falls on work plate. Depending upon the
requirement, the SLS component is allowed to undergo post processing operations
such as sanding, painting, etc.

Fig 2.2.2: WORKING PROCESS OF SLS MACHINE

 2.3MODELS IN SLS MACHINE

With advancement in technology, different models of SLS machines were

released by 3D systems, from basic level to high end models.

 Sinterstation 2500 plus SLS system and Vangaurd SLS system are the
basic level SLS models.
 Sinterstation HIQ series and
 Sinterstation HIQ+ HS are the upgraded versions
 SLS introduced under this series were Sinterstarion pro 140 and
Sinterstarion pro 230.
 Specifications of both the models under this series are same but pro 230
model is provided with comparatively larger build volume.

2.4 SPECIFICATIONS
 SPECIFICATIONS OF SINTERSTATION HIQ SERIES

1.Maximum build volume 381mm*30mm*457mm

2.CAD interface STL

S P
3.Laser CO2(type)
E CI
FI 30W( Power) C
A Standard TI
O N
Beam delivery system
S
4.Maximum speed of scan 5m/s

5.Electricity supply (Type) Alternative current (AC)

(Voltage) 240V or 380 V

(Frequency) 50Hz to60Hz

(Phase) 3

(Apparent power) 12.5KVA

OF SINTERSTATION HIQ + HS SERIES
 1.Maximum build volume 381mm*30mm*457mm

2.CAD interface STL

3.Laser CO2(type)

30W( Power)

High
2.5
Beam delivery system

4.Maximum speed of scan 10m/s

5.Electricity supply (Type) Alternative current (AC)

(Voltage) 240V or 380 V

(Frequency) 50Hz to60Hz

(Phase) 3

(Apparent power) 12.5KVA

COMPONENTS OF SLS

 Laser
 Part chamber
 Control system
 Build platform
 Levelling roller
 Power catridge
  Scanning system

2.6 MATERIALS USED IN SLS

Metallic and non metallic powders are used typically of the size 50µm.
Commonly used materials:
 Plastics
 Waxes (Investment wax casting)
 Low melting temperature metal alloys.
 Polymer coated metals.
 Ceramics (Green preforms).
 Nylon ( Duraform, Glass-Filled Nylon (Duraform GF), Flame
Retardant Nylon and Durable Nylon.)

2.7 ADVANTAGES:

 No support structure required.

 Parts obtained are tough.
 No post curing required.
 No tooling cost incurred.
 No wastage of material.
 Functional metal and ceramic parts can be obtained directly.
2.8 DISADVANTAGES:
 Surface finish is improper.
 Parts are porous in nature.
 Continuous monitoring of the building operation is required.
 Large amount of time is required to heat up material chamber
before building part.
 Uniform cooling is difficult to maintain in order to avoid warpage.
Parts obtained are brittle.

CHAPTER -3

LITERATURE REVIEW

Sanjeev Kumar [1] presented an article on “Selective laser sintering: a

qualitative and objective approach” In this article, a total review of SLS process is
discussed. Different materials for SLS process, binding mechanisms, preprocessing,
experimental parameters and post processing is discussed in detail. Sharanjit Singh[2]
presented a paper on “Investigation of Dimensional Accuracy/Mechanical Properties of
Part Produced by Selective Laser Sintering”. In this paper, the experimental investigation
of the SLS is carried out. A 25-100 Watt CO2 laser is used with polyamide powder as a raw
material. After testing, dimensional and mechanical properties are checked. Despa [3]
presented a paper on “study of selective laser sintering –A qualitative and objective
approach” In this paper, a synthetic review of the process of Selective Laser Sintering is
made. A deep review is taken on all the aspects of the SLS process that is from materials to
the post processing of parts. Various material are listed that can be used for SLS process.
Bonding mechanism is discussed in detail and a view on thermal modelling of amorphous
polymers is presented. Singh and. Chauhan [4] presented a paper on, “An overview of
rapid prototyping technology”. This paper provides an overview of rapid prototyping
technology in brief and emphasizes on their ability to shorten the product design and
development process. Classification of rapid prototyping processes and details of few
important processes is given. An attempt has been made to include some important factors
to be considered for proper utilization of potentials of rapid prototyping processes. Pandey
[5] presented report on “Rapid prototyping technologies, applications and Part deposition
planning”. This paper provides an overview of RP technology in brief and emphasizes on
their ability to shorten the product design and development process. Classification of RP
processes and details of few important processes is given. The description of various stages
of data preparation and model building has been presented. Tang [7] presented a paper on
“Direct laser sintering of copper based alloy for creating 3 Dimensional metal parts”. He
discussed the importance of direct laser sintering. Special copper based alloy is used for
rapid prototyping process. Produced parts are tested for different tests such as surface
roughness,mechanical properties to study the variation due to process parameters.
Paper on “Homogeneity aspects in selective laser sintering” is presented by S. Kolosov [8].
In this, a measure of powder layer homogeneity is proposed. Different layer deposition
techniques were checked for layer quality and thickness. Techniques used for deposition
were 1. Classical deposition 2. Pressure-gradient deposition 3. Ultrasound powder
compaction 4. Spread method etc. SEM images of all are studied. Powder layer quality is
measured by means of heterogeneity coefficient and results are discussed [8]. Murli [9]
presented paper on “Direct Selective Laser Sintering of iron-graphite powder mixture” In
which they presented a work on laser sintering of powder mixture of iron and graphite
(99.22 and 0.78% respectively) was carried out using a pulsed Nd-Yag Laser. In this
investigation, they attempted to produce and study an innovative metallic microstructure
from a mixture of iron and graphite powder by laser sintering by employing a pulsed Nd-
Yag Laser. They faced some problems. The products developed with these material suffer
from low a research work on rapid prototyping technology with laser additive manufacture
of wire based alloy Ti-6Al mechanical strength and durability. They can hardly be
employed for functional prototypes of engineering components. In some cases, post process
operations are necessary for achieving full density. Miranda et al. [10] presented a paper
“Rapid prototyping with high power fibre laser” in which they presented -4V with an 8 kW
fibre laser for the production of component with cylindrical geometry. High power fibre
lasers have considerable advantages in rapid prototyping, due to flexibility in beam
position and manipulation. Additionally these lasers have high power with low beam
divergence, high efficiency, low maintenance cost and small implementation space.

CHAPTER -4

METHODOLOGY

1. CAD Model
2. Conversion to STL file
3. Slicing models into layers (RP software)
4. Development of laser trajectory
 5. Building of model in the machine

Fig: 4.1: Methadology of Sls machine

CHAPTER-5

CONCLUSION

Consolidation regimes associated with SLS of aluminium alloys have been identified.
The variants of SLS/SLM process of aluminium alloys have been categorised on the basis of
Material component system, type of laser employed for consolidation, the intensity of the
Specific laser energy input dissipated on the powder bed, as well as laser induced in-situ
Chemical reaction for fabricating aluminium alloy-based composites. Knowledge of these
Variants provides basic understanding of overcoming associated challenges of fabricating
Aluminium alloy powders for various technological applications via the SLS/SLM process.
Available literature on SLS/SLM, powder metallurgy (P/M) sintering, and pulsed electric
current Sintering (PECS) of aluminium and its alloys were evaluated with a view to gaining
useful Insights especially in the aspect of alloying effect in disrupting the surface oxide film
barrier to Sintering or melting; liquid phase sintering (LPS); and alloying design suitable
for the SLS/SLM Process of aluminium powders. This led to highlighting the importance of
reducing the oxide Content of aluminium and its alloys during SLS/SLM processing.
Provided oxide levels are low and adequate amount of liquid phase is available for filling all
inter-particle pores completely, Components with inter-particulate bonding exhibiting pore
free microstructure across the layers are obtainable by SLS process. Furthermore, an
extensive analysis of the available literature on the direct SLS/SLM of Metals has led to the
recognition of the influential process parameters (processing atmosphere, Laser processing
parameters, layer thickness, and type of laser employed for the sintering Process) and
material properties (powder particle size and distribution, powder particle shape, Apparent
and tapping densities, powder flowability, chemical composition, and liquid phase Forming
additives). All the process and powder parameters reported above have been shown
Throughout the literature as having strong influences on the properties of metallic
powdered parts Fabricated via SLS/SLM with their effects being linked to what impact
each has over the wetting Conditions between the layers, density, surface roughness,
dimensional accuracy, surface Morphology, microstructure and mechanical properties.

CHAPTER-6

REFERENCES

[1] S. Kumar, (2003). Selective laser sintering: a qualitative and objective approach. JOM,
55(10), 43-47.
[2] S. Singh, A. Sachdeva, and V. S. Sharma, Investigation of Dimensional
Accuracy/Mechanical Properties of Part Produced by Selective Laser Sintering,
International Journal of Applied Science and Engineering 2012. 10, 1: 59-68.

[3] D. V, Gheorghe, Study of selective laser sintering –A qualitative and objective approach,
The Scientific Bulletin of VALAHIA University – MATERIALS and MECHANICS – Nr. 6
(year 9) 2011.

[4] V. K. Singh and N.S. Chauhan, An overview of rapid prototyping technology, IJAET
International Journal of Application of Engineering and Technology, vol-2 no.-3, ISSN:
2395-3594.

[5] P.M. Pandey, Rapid prototyping technologies, applications and Part deposition
planning.

[6] J.P.Kruth (1991) Material Incress Manufacturing by Rapid Prototyping Technologies,

CIRP Annals, Vol. 40, 2, pp 603-614.

[7] Y. Tang, H.T. Loh, Y.S. Wong, J.Y.H. Fuh, L. Lu, X. Wang, Direct laser sintering of a
copper-based alloy for creating three-Dimensional metal parts, Journal of Materials
Processing Technology 140 (2003) 368–372.

[8] S.Kolosov, G. Vansteenkiste, N. Boudeau, J.C. Gelin, E. Boillat, Homogeneity aspects in

selective laser sintering (SLS). Journal Of Materials Processing Technology 177 (2006) 348–
351.

[9] K. Murali, A.N. Chatterjee, P. Saha, R. Palai, S. Kumar, S.K. Roy, P.K. Mishra, A. Roy
Choudhury, Direct selective laser Sintering of iron–graphite powder mixture, Journal of
Materials Processing Technology 136 (2003) 179–185.

[10] R.M. Miranda, G. Lopes, L. Quintino, J.P. Rodrigues, S. Williams, Rapid prototyping
with high power fiber lasers, Materials And Design 29 (2008) 2072–2075.

[11] A.N. Chatterjee, Sanjay Kumar, P. Saha, P.K. Mishra, A. Roy Choudhury, An
experimental design approach to selective laser Sintering of low carbon steel, Journal of
Materials Processing Technology 136 (2003) 151–157.
[12] P. Bai, W. Wang, Selective laser sintering mechanism of polymer-coated molybdenum
powder, Trans. Nonferrous Mct. Soc.