RPT

UNIT – II
STEREO LITHOGRAPHY SYSTEMS
 Classification of Rapid Prototyping
Technologies

• Classification of Rapid Prototyping

Systems :
1. Based on Process
2. Based on Material
 Classification of RP- Based on Process
Class
1. Photo Polymerization process
2. Extrusion Process
3. Sheet Lamination Process
4. Printing Process
5. Powder bed sintering
6. Metal Deposition Process
Examples
SLA(Stereo lithography apparatus),
SGC (Solid Ground Curing)
FDM, FDC (Fused deposition of
ceramics)
LOM(Laminated Object
Manufacturing)
3DP (3D Printing),
BPM(Ballistic particle manufacturing)
SLS (Selective Laser Sintering),
DMLS(Direct Metal Laser Sintering),
SLM(Selective laser melting ),
EBM (Electron Beam Melting )
LENS (Laser Engineered Net Shaping)
DMD (Direct Metal Deposition)
Classification of RP- Based on Material
• There are various ways to classify the RP
techniques that have currently been
developed
• The RP classification used here is based on the
form of the starting material:
1. Liquid-based
2. Solid-based
3. Powder-based
 Liquid-Based Rapid Prototyping
Systems
• Starting material is a liquid
• About a dozen RP technologies are in this
category
• The following are described here:
- Stereolithography
- Solid ground curing
- Droplet deposition manufacturing
 Stereolithography (STL/SLA)

• RP process for fabricating a solid plastic part out of a

photosensitive liquid polymer using a directed laser
beam to solidify the polymer
• Part fabrication is accomplished as a series of layers,
in which one layer is added onto the previous layer to
gradually build the desired 3-D geometry
• The first addition RP technology - introduced 1987 by
3D Systems Inc. based on the work of Charles Hull
• More installations of STL than any other RP method
 Stereolithography Apparatus
operation
• Process begins with a solid model in various CAD
formats.
• CAD format transferred to .STL file
• .STL is oriented for optimum build, i.e., for better
placing in the –x,-y planes with minimum –z height
for less supports.
• The final .STL file is then sliced into horizontal cross
sections and saved as slice files.
• These slice files are then merged and downloaded
into the SLA to build the required part layer by layer.
Stereolithography Apparatus
operation
Build orientation
Build orientation
 Stereolithography Apparatus
Principle
• Stereolithography is a laser-based technology
that uses a UV-sensitive liquid resin.
• A UV laser beam scans the surface of the resin
and selectively hardens the material
corresponding to a cross-section of the product,
building the 3D part from the bottom to the top.
• The required supports for overhangs and cavities
are automatically generated, and later manually
removed.
 Principle
 Stereolithography Apparatus (SLA) process is the first
commercialized RP process

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SLA-Principle
 It works on the principle of solidifying a photosensitive resin using UV
laser light layer-by-layer to develop a 3D object.

 In this process, the laser light is moved in the X–Y plane by a

positioning system and the platform moves down as each layer is
formed in the tank containing the resin.

 The UV laser is controlled by a galvanometer scanner to generate X–Y

motion, and thus the table does not need to move in the x and y
directions.

 Stereolithography uses a photo curable resin that can be classified as

an epoxy, vinylether, or acrylate.

 Acrylics only cure about 75% or 80% since curing stops as soon as
the UV-light is removed.

 Epoxies continue to cure even after the laser is not in contact.

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• Stereolithography: (1) at the start of the process, in which the
initial layer is added to the platform; and
• (2) after several layers have been added so that the part
geometry gradually takes form
 The stereolithography process converts 3D computer image data into
a series of very thin cross-sections, much as if the object were sliced
into hundreds or thousands of layers.

 A vat of photosensitive resin contains a vertically moving platform.

 The part under construction is supported by the platform that moves

downward by a layer thickness (typically about 0.1 mm or 0.004 in.) for
each layer.

 A laser beam then traces a single layer onto the surface of a vat of
liquid polymer.

 The ultraviolet light causes the polymer to harden precisely at the

point where the light hits the surface.

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Step 1: The model is built upon a platform situated just below the
surface in a vat of liquid epoxy or acrylate resin.

Step 2: A low-power highly focused UV laser traces out the first layer,
solidifying the model’s cross-section while leaving excess areas
liquid.
The UV laser is controlled by a galvanometer scanner to
generate X–Y motion, and thus the table does not need to move
in the x and y directions.

Step 3: Next, an elevator incrementally lowers the platform into the

liquid polymer.

Step 4: A sweeper recoats the solidified layer with liquid, and the laser
traces the second layer atop the first.

Step 5: This process is repeated until the prototype is complete.

Step 6: Afterward, the solid part is removed from the vat and rinsed
clean of excess liquid

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 In all cases when a part is built, there is a small structure attached to
the bottom called the ‘‘supports.’’

 Their purpose is to raise the part Laser Lenses Mirror Part off the
platform and provide a ‘‘bridge’’ type structure that only touches the
part by small points.

 This structure is removed after the part is completed. Supports are

broken off and the model is then placed in an ultraviolet oven for
complete curing.

 The current stereolithography processes have advanced their

technologies. For example, the Viper Pro SLA system by 3D Systems
has adjustable beam size to accelerate part building speed. It has the
capacity to build a volume of 1500 x 705 x 500 mm3.

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( Acrylonitrile butadiene styrene )
 Stereolithography
SL
Summary
• 3D Systems, Valencia, CA
• patent 1986, beginning of RP
• photopolymerization using UV laser
• accuracy 0.025 mm
• epoxies, acrylates
 Some Facts about STL
• Each layer is 0.076 mm to 0.50 mm (0.003 in to
0.020 in.) thick
- Thinner layers provide better resolution and
more intricate shapes; but processing time is
longer
• The starting materials are liquid monomers
• Polymerization occurs upon exposure to UV light
produced by helium-cadmium or argon ion lasers
- Laser scan speeds typically 500 to 2500 mm/s
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 Renault for example, is using only SLA and Selective Laser
Sintering (SLS) models for their wind tunnel testing. 26
Picture of a statue using Stereolithography

http://home.att.net/~castleisland/faq/faq250.htm
SLA Machine
SLA Machine
SLA Machine
 SLA
Machine
SLA Machine
 Stereolithography Apparatus

The SLA apparatus consists of

1. Software (Data files)
2. Build Materials
3. SLA Hardware (Machine Details)

1. Software (Data files)

 For executing any of the required activities, there is an essence

of the software which converts the input commands into useful
practical functions with high precision and consistency

 The software requires effective control units and appropriate

tooling.
 The SLA control and the software related to this, have undergone many
developments along with the development of the operating software for
the computers

 In the initial period, the software was designed and developed to work in
the inception of MS-DOS version, Still most of the machines are working
with MS-DOS version .

 Initial there was a requirement of three softwares for the purpose of:

1. A UNIX based system for viewing and positioning (SLA viewTM)

2. Another UNIX based third party software for generating support

structure ( Bridge –WorksTM)

3. Slicing the SL file and operation system (SLA Slice)

 The next generation software Combined view/ positioning and support
generation.

 A more powerful UNIX- based software deemed MaestroTM, but for

operating the system the old DOS software was maintained.

 The latest system have Microsoft Windows NT software for all

operations.

3D Lightyear- wx ecutes all the required function of SLA process

like viewing and positioning (SLA view), generating support
and slicing

 These upgraded software's can still work on the older systems, by

generating codes for the old DOS operating machines
2. Build Materials
 Build materials are the raw materials which are used for developing
the SLA models

 SLA makes the prototype by adding material over the layer

 SLA is a liquid based RP process and uses photosensitive resins to

create prototypes

 In SLA process, the light energy is introduced by a focused laser,

which selectively cures the resin in a desired shape following a CAD
file.
 Builds parts directly by selectively curing, or hardening a
photosensitive resin with a relatively low-powered laser.

 Polymerization is the process of curing a plastic or polymer by

introducing a catalyst. In photo polymerization , the catalyst is light
energy.

 Under the influence of light of a specific wave length, small

molecules are polymerized into larger solid molecules.

 In the initial stages , acrylate based build materials was used in SLA.
Later an advanced epoxy-based material also known as ACES
(Acrylic Clear Epoxy System) is used
Few of the commonly used photosensitive resins are
 Ultra 10122
It is a next generation optically clear resin with Acrylonitrile
Butadiene Styrene (ABS) -like properties and good
temperature resistance.

It produces colorless, functional, accurate parts that

simulate an acrylic appearance.

It is ideal for applications requiring optical clarity, such as

automotive lenses, bottles, fluid flow analysis, packaging
prototypes, light pipes and more.

 Protogen 18420
It is a white colored photopolymer, providing considerable
processing latitude and has excellent tolerance to a broad
range of temperatures and humidity.

18420 Protogen is ideal for the medical, electronic, aerospace

and automotive market.
  SL 5530
High Temperature/ Transparent Polycarbonate-like material that
stands up to humidity, water and solvents, including automotive
solvents, optical clarity combined with high heat resistance.

Applications
 Intake manifold testing
 Wind tunnel testing
 Lighting fixtures testing (household and industrial)
 High temperature RTV molding
 Hot fluid flow visualization

 The desirable properties of the photosensitive resins are

 High temperature resistance
 Low viscosity
 Good water resistant
 Resistance to an automotive fluid
 Suitable for electrical applications
 Suitable for under the hood applications
3. SLA hardware (Machine Details)
 Stereolithographic apparatus consists of hardware control unit for
supporting the software execution, Laser unit (HeCd / Solid state),
deflection mirror (lens) and a machine.

 The machine has a perforated platform that has linear movement (up
and down), a sump containing the resin known as VAT, indicators on
the VAT to monitor resin level.

 A reactor blade runs on top of the fluid ensures a smooth surface

and indicates the level of the fluid

 The excess resins that get stuck on the surface of the models are
removed by immersing the models in an alcoholic bath or solvent
bath.

 The post processing has an ultra violet oven which is used for curing
the model.
 The build chamber with removal vat holds the build resin, a detachable ,
perforated build pattern on a –z axis elevator frame and an automated
resin level checking apparatus.

 This vat platform is moved down as each layer is formed in the tank
containing the resin.

 The laser light is moved in the X–Y plane and transferred to the part
surface below by a positioning system to scan the cross section of the
part being built.

 In some cases a support structure has to be created

to support the overhanging parts.

 Parts are then washed in the alcohol or a similar solvent immediately

after being removed from the machine.

 Finally the parts are required to be placed in an ultra violet oven called
the Post Curing Apparatus ( PCA) to finish fully curing.
Stereolithography Data Preparation
Stereolithography Data Preparation
Stereolithography Data Preparation
Stereolithography Data Preparation
 Data preparation and data files
 Most of the current CAD software can directly output an STL file from a CAD model, but
the actual command may change depending on various versions.

 The following examples are the methods used for generating an STL file in various CAD
files. (Note that these procedures are likely going to be version dependent)

Making STL files from SolidWorks

1. Click on File, Save As. Select the path to save the file.
2. For File Type, use the drop-down arrow, choose STL. Click Options.
3. Options—select Binary for file type. Binary files are approximately 1/5 the size of ASCII
files.
4. Options—Total Quality: Choices are Coarse, Fine, and Custom. Choosing Custom allows
access to Total Quality and Detail Quality sliders and fields. In most cases, selecting
Fine will produce an acceptable file, for custom try entering 0.001 in. or 0.002 in. for
Deviation, and 108 for Angle Tolerance.
5. Check the ‘‘Show STL Info Before File Saving’’ or ‘‘Preview’’ box to see a faceted view of
the STL file.
6. Select Done, and send the file to the RP machine.
Making STL files from Pro Engineer
1. Click on file, save copy.

2. Select the file type STL.

3. In the Export STL dialog box, set Format to Binary. Binary files are about
1⁄5 the size of ASCII files.

4. Set the Chord Height to 0.001 in. The field will be replaced by a minimum
acceptable value for the geometry of the model.

5. Set Angle Control to 0.5.

6. Name the file and click the OK button. Pro Engineer will save your STL
file, and display your triangles on the screen.
Making STL files from Unigraphics
1. Select File, Export, then Rapid Prototyping.

2. Make sure it is binary, set triangle to 0.001 in. or 0.025 mm.

3. Type in the file name, make sure the extension is stl, then select OK.

4. In class selection, select all, then OK.

5. Then discontinue, then OK.

 Concept of STL tolerance
 The left figure shows a rectangle representing the circle and the right
figure shows an octagon representing the circle.
 Here, two techniques are used to measure the closeness between each
of them
 The first involves measuring the distance between the tangent to the
circle and the side of polygon.

 Another technique is to find the angle made by the tangent to the

circle and the side of the polygon.

 The latter method serves as a good measure of the degree to which the
polygon represents the circle well.

 As a rule of thumb, triangles of a size between 0.02 mm (0.001 in.) and

0.05 mm (0.002 in.) will produce a good STL file.
There are two ways for users to control the tolerance of the triangulated
model, which
The users can input the maximum acceptable angle between the
model line and the tangent of the original curve.
The users can also input the maximum acceptable distance
between the model line and the original curve.

As the two figures

show, it is easy to find
that the smaller the
maximum value input
by users, the closer
the model line will be
to the original curve,
and consequently the
smaller the tolerance
will be.
CONTROLLING PART ACCURACY IN STL FORMAT
Using Pro Engineer as an example, there are two options, angle control
and chord height, to be specified when making an STL file.

The part shown below is used to illustrate the impact on the number of
triangles and the actual part by varying angle and chord height
The file contained a total of 1280 triangles. The representation is not as
smooth as the model, but it is a good estimation.
By making the chord length smaller, the number of triangles was increased
by two times, resulting in 2736 triangles.

With this file no noticeable difference was detected from the actual model.
For the third model the angle control was doubled. This netted similar
results to the first model with 1352 triangles.
To see what effect the angle control had, it was set at the other extreme of
0.05 in model 4.
This file looked the same as model 3 and contained 1296 triangles.
Therefore, in this case, the angle control does not have a major effect on
the model.
On the fifth model, the angle control was left at default and the chord
length was changed to 10. This resulted in 208 triangles and a round part
looking square as.
The chord length is set to 1 for the sixth model. This produced 2208
triangles and a slight circular distortion.
It can be seen that the chord length is a significant factor in the number of
triangles computed.
Common STL errors
 Sometimes there are errors when generating an STL file, and the errors will often need
to be corrected before further processing.
 All facets in an STL data file should construct one or more nonmanifold entities
according to Euler’s rule for legal solids:

F-E+V=2B
where F, E, V, and B are the number of faces, edges, vertices, and separate solid bodies,
respectively.
If the relationship does not hold, the STL model is ‘‘leaky,’’ and this will cause it to produce
slice boundaries that are not fully closed. Other examples can be seen in ‘‘degenerated
facets.’’
The type of degenerated facets include
(1) the three vertexes of the facet that are collinear or become collinear when the
previously nonlinear coordinates are truncated by the algorithm of importing the
application
(2) the three vertexes of the facet that coincide or become coinciding when the previously
noncoinciding coordinates are truncated by the algorithm of importing the application.
Another type of error is called

 Sometimes there are errors when generating an STL file, and the errors
will often need model errors.

 These types of errors are not generated during the STL conversion
process, but rather inherited from the incorrect solid models themselves,
often due to the designer’s errors.

 These errors may cause inconvenience to the RP process. The RP

machine may build a bad part or may even stop building the part.

 Once the STL file is obtained, the next step is to select the build
direction.

 Often, a surface of the largest area of a part is chosen as the bottom

surface and the part is then built along the Z-direction.
Is there need for proper orientation of part model?
 In most RP processes, the Z-direction is usually the weakest axis for
tensile strength.
 Keeping this in mind, the user will rotate the part to fit within the build
chamber, and also keep the higher required strength of the part in the x–
y plane of the build.
 The build time is also dependent on how much support material is
deposited. Part layers build much faster after the support material has
been completed and the machine does not require a material change in
the same layer.
 Therefore, to save support material and build time, the user usually
needs to keep the support material to a minimum, at least a minimum
height in the Z-direction.
 On the other hand, one cannot sacrifice the quality of the part in order to
reduce support material height; otherwise one may end up with a pile of
filament or bad surface finish.
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 Stereolithography Process parameters
 Laser Beam Spot Diameter

 Laser Beam Focus Depth

 Layer Thickness

1. Laser Beam Spot Diameter

• Fixed at 200 µm for most SL systems.

• Because of scanning, the smallest feature that can be built is

around 1.5 times the laser diameter, around 300 µm

• In high resolution systems such as 3D systems viper Si2

machine, the laser beam spot diameter is 75± 15 µm , hence the
features as thin as 80 µm can be built.
2. Laser Beam Focus Depth
• In the Z direction, the curve depth of a layer is a function of the
focus depth underneath the resin surface.

• The attainable layer depth is inversely proportional to the depth

of focus of the laser beam.

• The laser beam is focused beneath the resin surface in order to

increase the Rayleigh range and the accurate build platform size.

• The focus distance is usually 8mm below the resin surface.

3. Layer Thickness
• Thickness of one layer is inversely proportional to the depth of
focus of the laser beam under the resin surface.

• Layer thickness is mainly limited by the recoating mechanism

and the resin viscosity.

• SLA machine uses a blade to sweep the excess resin from the
top of the build before a layer is built to ensure that the build
surface is flat.

• Smallest possible thickness- 0.001 inch

• It affects the surface texture, accuracy in the z-axis and the build
speed.
Ideal applications for Stereolithography
• Visual prototypes for photo shoots and market
testing
• “Show and tell” parts with smooth surfaces and
fine details
• Prototypes for limited functional testing
• Masters for copying techniques such as Vacuum
Casting
• Alternatives for sheet metal prototypes when
coated with a metal plating process
• Patterns for investment casting
• Low-volume production of complex geometries
Advantages
Advantages
Disadvantages
 Selective Laser Sintering
• Selective laser sintering (SLS) is an additive
manufacturing (AM) technology that uses a
laser to sinter powdered plastic material into a
solid structure based on a 3D model.
• SLS has been a popular choice for engineers
in product development for decades.
• Low cost per part, high productivity, and
established materials make the technology
ideal for a range of applications
from functional prototyping to small batch or
bridge manufacturing.
 SLS- A powder bed fusion system
• Work with a range of materials: plastics, metals, glass,
ceramics, and various composite material powders.
• Categorized as powder bed fusion—additive
manufacturing processes by which thermal energy
selectively fuses regions of a powder bed.
• The two most common powder bed fusion systems
today:
1. Plastic-based : SLS,
2. Metal-based : Direct metal laser sintering (DMLS)
or selective laser melting (SLM).
• Both of these systems have been prohibitively
expensive and complex, limiting their use to small
quantities of high value or custom parts, such as
aerospace components or medical devices.
 What materials are used for SLS?
• A major distinction between selective laser sintering and other
rapid prototyping technologies is the variety of materials that can
potentially be processed.
• Wax: create visual models
• Polycarbonate: create visual models, functional prototypes
• Nylon: create visual models, functional prototypes
• Acrylic: create visual models, functional prototypes
• Elastomer: flexible, rubber-like prototypes and parts
• Metals (RapidSteel and Copper Polyamide): metal molds and
tools, prototypes or final parts
• Sand: casting patterns, sand casting cores, and molds
 SLS: Type of machine
• All selective laser sintering systems are built
around the process of sintering powdered
plastic material into a solid structure based on
a 3D model by using laser.
• The main differentiators are
1. The type of laser
2. The size of the build volume.
• Different systems employ different solutions
for temperature control, powder dispensing,
and layer deposition.
 SLS: Type of machine
• Selective laser sintering requires a high level of
precision and tight control. The temperature of
the powder along with the (incomplete) parts
must be controlled within 2 °C during the three
stages of preheating, sintering, and storing before
removal to minimize warping, stresses, and heat-
induced distortion.
• SLS is categorized into
1. Industrial SLS
2. Benchtop SLS
 1. Industrial SLS
• Industrial SLS has been in use for numerous
applications, from spare parts for the world's biggest
truck maker to custom-printed clothing.
• The largest systems can print 1-meter-long parts.
• Industrial SLS systems use a single or multiple high-
power carbon dioxide lasers.
• The larger the build volume, the more complex the
system.
• Industrial SLS requires an inert environment–nitrogen
or other gases–to prevent powder from oxidizing and
degrading.
• Thus, industrial selective laser sintering calls for
specialized air handling equipment.
• These systems also require industrial power; even the
smallest industrial machines need at least 10 m²
installation space.
1. Industrial SLS
 2.Benchtop SLS
• Benchtop SLS systems achieve output comparable to
industrial systems in a more compact, manageable form.
• Benchtop systems use a diode or fiber laser instead of the
CO2 lasers used by industrial systems to provide equal beam
quality at a lower cost.
• A benchtop machine's smaller build volume requires less
heating.
• As the powder gets exposed to elevated temperatures for a
shorter period of time, there is no need for inert gases and
specialized air handling equipment.
• The overall less energy consumption allows benchtop
systems to run on standard AC power with no specialized
infrastructure.
• Overall, benchtop systems offer a slightly reduced build
volume and slower speed compared to the smallest
industrial SLS systems, in return for a substantially smaller
footprint and lower cost.
2.Benchtop SLS
Comparison of SLS Systems
 SLS: Principle of operation
• SLS 3D printers use a high power laser (co2 laser) to
fuse small particles of polymer powder.
SLS: Principle of operation
 The Print Process
• Powder is dispersed in a thin layer on top of a platform
inside of the build chamber.
• The printer preheats the powder to a temperature just
below the melting point of the raw material. This
makes it easier for the laser to raise the temperature of
specific regions of the powder bed as it traces the
model to solidify a part.
• The laser scans a cross-section of the 3D model,
heating the powder to just below or right at the
melting point of the material. This fuses the particles
together mechanically to create one solid part.
• The unfused powder supports the part during printing
and eliminates the need for dedicated support
structures.
 The Print Process
• The platform lowers by one layer into the
build chamber, typically between 50 to 200
microns, and a recoater applies a new layer of
powder on top. The laser then scans the next
cross-section of the build.
• This process repeats for each layer until parts
are complete, and the finished parts are left to
cool down gradually inside the printer.
• Once parts have cooled, the operator removes
the build chamber from the printer and
transfers it to a cleaning station, separating
the printed parts and cleaning of the excess
powder.
Part Recovery and Post-Processing
• Selective laser sintering post-processing requires
minimal time and labor, and leads to consistent results
for batches of many parts.
• After a print job is complete, the finished parts need to
be removed from the build chamber, separated, and
cleaned of excess powder. This process is typically
completed manually at a cleaning station using
compressed air or a media blaster.
• SLS parts have a slightly rough, grainy surface finish
right out of the printer similar to a medium grit
sandpaper. Nylon provides a range possibilities for
post-processing, such as tumbling, dyeing, painting,
stove enameling, metal coating, bonding, powder
coating, and flocking.
 Material Recovery
• Any excess powder remaining after part
recovery is filtered to remove larger particles
and can be recycled.
• Unfused powder degrades slightly with
exposure to high temperatures, so it should be
refreshed with new material for subsequent
print jobs.
• This ability to re-use material for subsequent
jobs makes SLS one of the least wasteful
manufacturing methods.
SLS Machine
SLS: Process parameters
SLS: Process parameters
SLS: Process parameters
 SLS: Process parameters

Laser Scan Speed

• Operating at lower laser
powers require the use of
lower scan speeds in
order to ensure proper
particle fusion.
•Melt pool size is highly
dependent upon settings
of laser power, scan
speed , spot size and bed
temperature.
SLS: Process parameters
 SLS: Process parameters
• Powder shape, size and size distribution strongly influence
laser absorption characteristics, powder bed density and
powder spreading.
• Fine particles provide greater surface area and absorb laser
energy more efficiently than coarse particles
• The powder bed temperature should be uniform and constant
to achieve repeatable results.
• High laser power or high bed temperature results in high
density parts but poor recyclability.
• Low laser power or low bed temperature produce low density
but highly accurate parts.
Powder Shapes
SLS: Data preparation for SLS
 SLS: Applications
• Why Choose SLS?
Engineers choose selective laser sintering for
its design freedom, high productivity and
throughput, low cost per part, and proven
track record.
 Design Freedom
• Most additive manufacturing processes, such
as stereolithography (SLA) and fused
deposition modeling (FDM), require
specialized support structures to fabricate
designs with overhanging features.
• Selective laser sintering does not require
support structures because unsintered
powder surrounds the parts during printing.
SLS can produce previously impossible
geometries, such as interlocking or moving
parts, parts with interior components or
channels, and other highly complex designs.
• Engineers generally design parts with the capabilities of the final
manufacturing process in mind, also known as design for
manufacturing (DFM).
• When additive manufacturing is used for prototyping alone, it is
limited to parts and designs that conventional manufacturing
tools can ultimately reproduce during production.
• SLS can print complex designs in a single
print that would normally require
multiple parts. This helps alleviate weak
joints and cuts down on assembly time.
• Selective laser sintering can take
generative design to its full potential by
enabling lightweight designs that
employ complex lattice structures
impossible to manufacture with
traditional methods.
 High Productivity and Throughput
• SLS is the fastest additive manufacturing technology for
functional, durable prototypes and end-use parts.
• The lasers that fuse the powder have a much faster
scanning speed, and are more accurate than the layer
deposition methods used in other processes like industrial
FDM.
• Multiple parts can be tightly arranged during printing to
maximize the available build space in each machine.
• Operators use software to optimize each build for the
highest productivity leaving only minimal clearance
between parts.
• Parts can be added to the build while printing is already in
progress. This provides the opportunity for last minute
design changes or to add consecutive iterations of a
prototype.
High Productivity and Throughput

SLS allows operators to

pack the build chamber
with as many parts it can
fit and print them
without supports to save
time in post-processing.
 Proven, Long-Lasting Materials
• The key to SLS 3D printing’s functionality and
versatility is the material.
• Nylon and its composites are proven, high-quality
thermoplastics.
• Laser-sintered nylon parts have close to 100 percent
density with mechanical properties comparable to
those created with conventional manufacturing
methods like injection molding.
• SLS nylon is a great substitute for common injection
molding plastics.
• It offers superior living hinges, snap fits, and other
mechanical joints compared to any other additive
manufacturing technology.
• It is ideal for functional applications requiring plastic
parts that will last where parts produced with other
AM methods would degrade and become brittle over
time.

Drill assembly printed in

Nylon PA 12. Nylon parts
can be easily post-
processed to achieve
smooth, professional
surface finishes.
 SLS –Parts (Nylon material)

• Nylon is ideal for a range of functional applications, from

engineering consumer products to healthcare.
 SLS vs. SLA
• One major difference between SLA and SLS
revolves around material selection.
• SLA works with polymers and resins, not metals.
SLS works with a few polymers, such as nylon
and polystyrene, but can also handle metals like
steel, titanium, and others.
• SLA works with liquids, while SLS uses powders
that raise safety concerns. Breathing in fine
particulates of nickel, for example, can be
harmful. Breathing apparatus and ventilation
should be considered, depending on the type of
powder.
• SLA liquid photopolymers cost $80 to $100 or
more per liter. SLS powders costs between $300
and $600 per kilogram, and can be difficult to
even purchase.
• Although both 3D techniques use lasers, they
operate at different wavelengths. As mentioned,
SLA lasers operate in the UV wavelengths to
cure epoxy within a resin. SLS relies on higher-
powered lasers to compact and sinter metal
powders. Therefore, SLS generally requires high
peak energies to physically compress metal
powders, while SLA can be used at lower peak
powers depending on the photosensitive
polymer.
SLA SLS
 Fused Deposition Modeling
• Fused Deposition Modeling
(FDM), is the most
commonly used 3D printing
technology.
• An FDM printer takes a
filament of a material
(usually plastic) and
extrudes it through a print-
head-like nozzle. This
material is then laid down in
thin layers to form a 3D
object on a platform, built
from the bottom up.
 History of FDM
• Fused deposition modeling was developed by S. Scott
Crump in the late 1980s before he founded Stratasys.
• With Stratasys, Crump commercialized FDM in 1990,
where the company continue to dominate the industry
today.
• Another big year for 3D printing using fused deposition
modeling was 2005, the year the RepRap movement
started.
• The RepRap movement is based on the open source
community and involves 3D printing parts to your own
3D printer. Once you have 3D printed your own 3D
printer, you are morally obliged to print the pieces to
another 3 for other people.
• This RepRap 3D printer uses FDM technologies to 3D print
more copies of itself in a process of self-replication.
FDM 3000 Machine by Stratasys
Part orientation
Extrusion Head
Overall FDM Process
Overall FDM Process
 FDM Applications
For concept or design visualization
 FDM Applications
For Direct use components
FDM Applications- in Food sector
FDM Applications- in Food sector
FDM Applications- in Food sector
FDM Applications- for investment
casting patterns
FDM Applications- in biomedical field
FDM Applications- in jewelry
Latest FDM Machine
FDM
FDM vs SLA vs SLA