Fraunhofer Institute for Laser Technology ILT
Fraunhofer Institute for Laser Technology ILT

Selective Laser Sintering

AM polymer components free of support structures – from individual parts to series production

Selective laser sintering (SLS) is a tried and tested additive manufacturing technology that can be used to produce polymer components efficiently and without support structures. In SLS, powdered plastic is locally fused or sintered by a precise laser – layer by layer. This method enables users to produce functional prototypes, small batches and customized individual parts for a wide range of applications.

Materials research for selective laser sintering: Innovative materials for new applications

© Fraunhofer ILT, Aachen

In its research on SLS, Fraunhofer ILT currently developing and qualifying new materials for the process, for example, typical polymers such as polyamide (PA12, PA11), thermoplastic polyurethane (TPU) or bioresorbable materials (PLA, PCL). The institute is specifically adapting them to the requirements of various industries. The institute aims not only to meet requirements specific to the industry, but also to make materials more sustainable, more stable and more efficient to process.

The institute is also researching how sustainable new materials – such as bio-based polymers, highly filled plastics and polypropylene (PP) – are when used in SLS processes. In this way, it is specifically classifying material classes for special applications and expanding the possible uses of SLS components.

Fraunhofer ILT has extensive expertise in the characterization and evaluation of SLS materials. In addition to investigating powder properties such as particle size, flow behavior and thermal properties, the institute also analyzes component properties. These investigations provide important data for quality assessment and help to improve manufacturing processes and adapt new materials to specific applications.

Versatile system technology for flexible SLS processes

Fraunhofer ILT uses a wide range of system technology to fully address research questions and industrial requirements in the field of SLS. This includes both laboratory systems developed in-house and commercial machines, from low-cost systems to high-end industrial systems for series production and high quality requirements. Thanks to this broad technical basis, the institute can determine process parameter windows and specifically analyze the influence of process parameters on component quality in order to adapt the component properties to different operating conditions. Fraunhofer ILT supports companies in selecting suitable machines and process strategies.

By transferring many years of expertise from metal-based additive manufacturing, the institute can also apply proven approaches to polymer processing. One focus is on process monitoring for the purpose of quality assurance. The institute offers an integrated approach, materials, systems and processes – resulting in customized solutions for specific requirements and materials.

© Fraunhofer ILT, Aachen

Areas of application for selective laser sintering (SLS)

Selective laser sintering can provide various industries with a wide range of applications:
  • Automotive industry and aerospace industry: SLS enables the industry to rapidly produce functional prototypes and small series as well as topology-optimized components that meet high requirements for weight savings and stability.
  • Medical technology: Patient-specific implants, prostheses and orthoses can be manufactured from biocompatible or bioresorbable materials and, thus, offer individual solutions for medical care.
  • Mechanical engineering: Functional components and spare parts are manufactured directly without the use of tool-based production steps. This shortens development times and makes production processes more efficient.
  • Consumer goods: Wearables, sporting goods, tailor-made furniture components, ergonomically optimized shoes and soles as well as lifestyle products benefit from design freedom.

Would you like to make targeted use of SLS for your applications or gain insights into our latest research results? Fraunhofer ILT consults individually and comprehensively, also evaluates technology, all to optimize your manufacturing processes. Are you interested in other additive manufacturing processes? In cooperation with FH Aachen – University of Applied Sciences, our researchers and project partners have various processes and systems at their disposal. Our experts are available for specific research inquiries or in-depth discussions. Contact us and let us develop customized solutions together.

© Fraunhofer ILT, Aachen