SELECTIVE LASER SINTERING

Sintering
• The thermal treatment of a powder or
compact at a temperature below the
melting point of the main constituent, for
the purpose of increasing its strength by
bonding together of the particles.
 Selective Laser Sintering (SLS)

1. Piston of the part built

chamber lower by one layer; Scanning Laser
Mirror
2. Piston of powder cartridges
raise up;
3. Roller spread powder evenly
over the built surface; Roller
4. Laser beam scan over the top

Support
of the part, melting the

Part
powder and fuse it to the
previous layer;
5. Loop through the four steps
Powder Build
to build the next layer. cartridges Piston Chamber

3
• Sintering of metals and ceramics powders
requires as much longer period time.
• The metal and ceramic powder are coated
with a very thin layer of polymer binder.
• Wide range of materials like waxes, metal
and ceramics then wide variety of polymer
material like nylons polyamide,
polycarbonate, elastomers and acrylic
styrene.
 Basic types of SLS
• Direct SLS
• Indirect SLS
 INDIRECT SLS
• Indirect SLS was developed by university of texas and
commercial machine was offered in 1995.
• In this technique metal powder are mixed with small
amount of polymer alternatively metallic and ceramic
powder are coated with polymer.
• Particle binding occurs essentially through polymer-
polymer bonds. For instance during SLS of a steel powder,
the powder softens and forms necks between adjacent
particles.
• The resulting part is called the green part owing to melting
of polymer the green part is usually quite porous. Hence it
cannot be used without some post processing.
 Post Processing
• Since SLS process yield green parts with
significant porosity, they need to be post
processed. So as to built part strength.
• Post processing involve some or all of
following four steps.
– Binder removal.
– Sintering of remaining metals.
– Powder infiltration.
– Surface finishing.
 Removal of Binder
• The polymer binder can flow out of green part under the
action of gravity combined without distortion.
• Polymer binder decomposes 2-3 times faster in air than in
the natural atmosphere such as nitrogen used in the
system. some ceramics no need for natural atmosphere.
• Parts to be sinter are usually packed in alumina and then
placed in a cold oven.
• Next the oven is heated to 200˚C and held there for 3-4
hours to let the polymer drain into the packing material.
• Little polymerization occurs at this temperature , next the
part is heated at a rate of 100˚c/hr to higher
 Sintering
• During sintering stage, microscopic welds form at particle
contacts. The neck so formed lead to atomic diffusion even
in the absence of isostatic pressing until the neck structure
has formed.
• The part are too weak to be handled however there
remains sufficient porosity that could be filled through
subsequent infiltration.
• In relative density exceed 90% interconnections between
pores become unstable, so the pores become isolated and
mass transport mechanism such as evaporation,
condensation and surface diffusion stops.
 Infiltration
• It can be done from the top or the side
• If done from the top, infiltration should be
done in a separate furnace where the lower
melting infiltration medium is placed on
the top of the powder.
• If done from side the debinding, sintering
and filtration steps can be performed in the
same furnace.
 Surface finish
• Bead blasting is used to remove excess powder
embedded in part surface.
• Abrasive tumbling is used to improved finish on
all accessible surface.
• However these two processes can damage small
features such as sharp corners on the part etc.,
• Pores and stair steps can be covered by means of
surface coating.
• Hand sanding is used to remove excess material as
well as to obtain improved finish
 DIRECT SLS

It utilizes a high energy laser beam to directly consolidate a metal or cement powder to
densities grater than 80% of theoretical density.
1. The advantage is that many of the pre and post processing steps associated with the
indirect SLS eliminated.
2.note that, in contrast to conventional sintering no compaction pressure is applied in
SLS. As a result the green parts are of lower density they are nearly isotropic and free
from internal Stresses.
3. The Key advantage of SLS is that is capable of yielding functional parts is essentially
final materials. It is Possible to produce parts considerably stronger than those
produced by SLA. Further the process is considerably stronger than those produced by
SLA. Further the process is simple. E.g., there are no milling or masking steps required
Living hinges are possible when thermoplastic like material are used. Uncured metal
is essentially removed after a build by brushing or blowing it off.

WHY SLS:
Prototype may also be used for display marketing purpose. One of
the best features about rapid prototyping is its turn around time. Turn around
time has been reduced to hours, and days. Instead of weeks or months,
resulting in the ability to do multiple, design iterations. Also the time and cost
of the models are so reasonable as to large experiments.
FIT:
SLS prototypes can be most beneficial and provide the most comfort when
a designer cannot gage product tolerances but wants to verify that two or more
parts will fit together. One of the values of building.

FORM:

Products are designed with a specific form in mind whether it is to

hold material or liquid, join parts or protect components, they are designed a
particular way for specific reasons. Building an SLS prototype model prior to
investing time and money in final production tooling, equipment, and
material allows the designer to see first hand if the product as designed will
meet the desired intension. When designing parts nothing builds confidence
like a part that can be touched and held. Here is where a prototype has its
greater value. The prototype may also enlighten the engineer, to design the
part differently to achieve the final objective. All SLS material are good to
examine form and verify the part will achieve the desired intention.
This list includes:
1. Dura form with excellent surface finish.
2. DuPoint somas with “rubber-like” characteristic
3. Fine and Medical grade nylon for good detail.
4. True form has smooth masters that are used for investment easting and
soft tooling
5. Sand form used for fabricating prototyping sand cores and molds.

FUNCTIONS:
In many instances finite element analysis (FEA) programs are
not enough to verify the final products functionality. In those cases three-
dimensional SLS prototype are created to test the functionality and verify
tolerance dimensions. This Situations is certainly preferred to mounting
until large investments of time and many are made to manufacture the first
production, products, only to final they do not function as intended.
Appearances:
SLS prototypes can be finished with a desired texture
and painted different colors to achieve the final product look in
instances where appearances are important. SLS prototype offer an
advantage on new texture designs that requires approval on the final
appearance because it allows for changes prior production. Dura form,
fine Nylon, Composite Nylon, True form and DuPoint Somas.
FLEXIBLE MATERIALS:
Dupont Somos:
This material is used for seals, gaskets,
moldings, athletic, sole , toys, rubber, parts, models, and applications
where “rubber-like” flexibility is required as well as for use in place of
silicone and urethane material.

RECENT APPLICATIONS:

• 1. Gear Shift Boots

• 2.Heart Valves
• 3. Window Moldings
• 4. Extrusion

Dura form polyamide dura from polyamide is used to make functional

models with un matched feature definition of any other Selective
Laser sintering material. Parts are dura form has been certified VSP
level for limited in vivo experiment.
FINE NYLON MEDICAL GRADE AND MEDICAL GRADE:

A fine grade nylon recommended for functional parts requiring durability

and fine detail along with thermal stability and chemical resistance i.e. ,
snap fits and living hungers
ADVANTAGES
 This process has also applied successful to powders made up of steels,
Ni-Based Super alloy. Ti and its alloys, cermets and refectory bronze –
N
 As built material properties can be quite close to those of the intrinsic
materials.
 One does not need to incorporate support since the powder bed itself
supports over hanging sections of the parts.
 The completed point also exhibits reduced distortion from stresses.
The SLS is capable of producing functional parts and tool inserts
finally.
DISADVANTAGE

1. It is more mechanical complex.

2. SLS parts suffer from the stair -stepping problem
3. Surface finish and accuracy are not quite as good as with
SLA
4. The First layer mainly require a base anchor to reduce
thermal effects, such as curling,. SLS parts exhibit
powdery, porous, surface that are absorbed and mark
easily
5. The porosity and hence the density can vary a cross part
6. Finally a change in part material requires through
cleanings of M/C
POWDER STRUCTURES:

FOUR POSSIBLE TWO-PHASE STRUCTURES:

(a). The Primary metallic phase is coated with a metal or polymer

binder with lower melting point so as to facilitate binding. This
approach is not only expensive but also brings problems arising for
non uniform coating thickness.

(b). Mixing the two components mechanically, this approach

yields high packing density, even higher densities can be obtained
by vibrating the bed. However the component can get segregated
while the wiper spreads it over the table.

(c) and (D): The problem of segregation does not occur when a
pre-alloyed powder is used. Pre Alloying can also be used to
reduce oxidation of metallic powders for instance, oxidation of
copper powder during sintering is found to decrease when pre
alloyed with tin.
Laser Engineered Net Shaping
 How It Works
• Uses a high power laser to melt metal powder
that is deposited onto the table. Metal is
sprayed onto the focal point on the laser where
the metal becomes fused together. An inert
gas is used to shield the metal from
atmospheric gases. It uses a layered approach
to manufacture the components.
• A high power laser is used to melt metal powder supplied
coaxially to the focus of the laser beam through a deposition
head (C).
• The laser beam typically travels through the center of the head
and is focused to a small spot by one or more lenses (B).
• The X-Y table (D) is moved in raster fashion to fabricate each
layer of the object.
• Typically the head is moved up vertically as each layer is
completed. The laser beam may be delivered to the work by any
convenient means.
• A simple right angle mirror (E) is shown,.Metal powders (A) are
delivered and distributed around the circumference of the head
either by gravity, or by using an inert, pressurized carrier gas
(G).
• Even in cases where it’s not required for feeding, an inert gas
(F) is typically used to shield the melt pool from atmospheric
oxygen for better control of properties, and to promote layer-to-
layer adhesion by providing better surface wetting.
 Materials
• Stainless Steel 316 alloy
• H13 Tool Steel
• Titanium with 6% Aluminum and 4%
Vanadium
• Copper
• Inconel
 Advantages of LENS
• Can be used to repair parts as well as fabricate
new ones
• Has a very good granular structure
• Powder forming methods have few material
limitations
• Doesn’t require secondary firing operations
• The properties of the material are similar or
better than the properties of the natural
materials
 Disadvantages of LENS
• Some post processing involved
• The part must be cut from the build substrate
• Has a rough surface finish, may require
machining or polishing
• Current maximum wall angle is 18 degrees
• Low dimensional accuracy