Flashback to episode 3

In Part 3, we compared the low-cost “FDM” with the high-resolution “SLA (Light Assurance Modeling)”.

FDM: Cost-effective but rough surface
SLA: Beautiful surface, but limited by the strength and durability of the material.

But if we want to produce practical parts, such as jigs or small quantities of finished products, which 3D printing technology should we choose? The answer is "SLS (Sintered Powder Laminating)" technology!

1. What is SLS?

Selective Laser Sintering (SLS) is a 3D printing technology focused on creating parts from high-strength nylon, a material widely used in industrial applications, not just for prototyping. It's a popular technology for engineering applications that require durability and reliability.

Working principle

The way SLS works is interesting because it is different from conventional 3D printers that spray plastic filament or use liquid resin.

Inside the printer, nylon powder, such as PA11 or PA12, is sprinkled in a thin, even layer over the entire surface. A high-powered laser beam then hits the specific shaped parts of the part in each layer, causing the nylon powder to melt and bond together instantly.
When one layer is completed, the machine sprinkles a new layer of powder and repeats the process until the piece is completely formed.

The result is a strong, durable nylon part that is ready for immediate use, from mechanical assembly to factory jigs.

Outstanding advantages of SLS

SLS solves two major problems that FDM and SLA previously faced:

Advantages (1) No need for a single support.

One of the key advantages of SLS over other methods is that it doesn't require any supports at all. In FDM or SLA technologies, creating parts with floating parts requires a "frame" or support to support them. After printing, these parts must be gradually removed, point by point, sometimes causing surface damage or adding more complicated finishing steps.

But SLS uses the remaining powder material around the part as a structural support instead of natural support.
The result is the ability to create previously difficult pieces such as:

• Complex internal structure
• Movable parts such as hinges and assembly components

All of this can be printed simultaneously, without separate printing or assembly, saving time, labor, and truly allowing for more design freedom.

Advantages (2) Extra strong and durable.

Another key reason why SLS has gained industrial acceptance is its strength and durability. Using nylon, an engineering plastic known for its high mechanical properties, the resulting parts not only have aesthetic appeal but also possess excellent strength, durability, and temperature resistance.

Unlike FDM or SLA, which are mostly suitable for prototypes to see the design or test the initial assembly, SLS parts go much further because they can be used immediately in real-world applications, such as:

• Jigs / Fixtures that require force and are used in factories
• Functional parts such as gears, clamps, or locks.
• End-use parts that require real-world durability

This strength advantage makes SLS an ideal choice for businesses looking to produce parts for actual use, not just for testing or demonstration purposes.

From the original limitations to the Formlabs “revolution”

Despite the power of SLS technology, it was once considered out of reach for many organizations. Most SLS machines are as large as a wardrobe and cost tens of millions of baht, making them only available in large factories or research centers. This is why many businesses, even those seeking to produce high-quality nylon parts, lack access to this technology.

But Formlabs has completely changed that picture with the Fuse 1+ 30W.
The SLS machine is designed to be compact, can be placed in an office, and most importantly, it is more affordable, at a level that ordinary businesses can afford to invest in, unlike traditional SLS machines that are out of reach.

Another key turning point is the highly efficient powder recycling system, which can reuse up to 70% of used powder.
This significantly reduces the cost per unit of production, making it a cost-effective solution for small businesses, design departments, and in-house engineering teams looking to produce their own functional nylon parts.

Formlabs is not only bringing SLS to a new market, but also making “in-house industrial production” a reality for every business.

2. Other industrial technologies

In addition to SLS, there are other manufacturing technologies used in specialized applications, including:

Material Jetting

• Highlights: Excellent in “full color” and “texture”
• Principle: Spray drops of UV cured resin onto the desired location, similar to an ink printer.
• Advantages: Full color printing from thousands to hundreds of thousands of colors. Can mix materials such as hard resin + rubber resin in one piece.
• Disadvantages: Uses resin material, making it not very strong and durable.
• Suitable job: Design model to see the look and feel of the product.

Binder Jetting

• Highlights: Used for “mass metal production” or “sand casting for casting”.
• Principle: Similar to SLS, but uses “glue” sprayed onto metal powder or sand to hold it in shape.
• Advantages: Very fast, suitable for high-volume production.
• Disadvantages: Freshly printed parts are not very strong and must go through the process of removing the binder and firing in a high temperature oven before they can be used.

Conclusion: Each technology is suitable for different tasks.

• FDM : Low cost, suitable for shape inspection.
• SLA (Form 4) : Very high resolution, suitable for designs and work that requires precision.
• SLS (Fuse 1+) : Strong, durable nylon, no support, suitable for real-world applications.
• Material Jetting : Realistic color and texture models
• Binder Jetting : Produces large quantities of metal or sand casting, but requires baking and firing after printing.

Each technology has its own advantages. The choice of use depends on the “goal” and “format” that needs to be produced.

Next article

In Part 5, we'll summarize all the information we've gathered so far and recommend the most suitable 3D printer for you, based on specific business needs or challenges, such as "requiring high-resolution prototypes" or "needing to manufacture robust fixtures in-house." This will help you choose the 3D printer that best meets your needs at this time.

References

1. In the next 3D version, 3D characters will appear in the app ~22選 - Japanese version,
   https://grape-piyo.com/3dp-goods/

2. What is the meaning of SLS?
   https://www.yam-sls-3dprinter.com/post/blog-20241023-sls-technology

3. 3D Japanese translations of Japanese characters and Japanese characters.
   https://www.dent3d-navi.com/example/

4. What is the meaning of the word? SLS（粉末焼結積層法） and has a 3D 3D animation - Printed online at https://emtopia.net/yougoshu/sls-printing

5. 3D characters are created in different ways | 3D プリンター・3D プリントならi-MAKER
   https://i-maker.jp/blog/select-3dprint-make-33988.html

6. Formlabs SLS - Brule,
   https://www.brule.co.jp/learn/3d-printing/formlabs-sls.html

7. 3D print method https://i-maker.jp/blog/select-3dprint-method-33992.html

8.  https://www.brule.co.jp/formlabs/formlabs-fuse-1-plus-30w-sls-selective-laser-sintering-3d-printer-package.html#:~:text=Fuse%201%2B%2030W%E3%81%AF%E3%80%81%E6%9C%80%E5%A4%A7,%E7%A4%BE%E5%86%85%E3%81%A7%E5%AE%9F%E7%8F%BE%E3%81%A7%E3%81%8D%E3%81%BE%E3%81%99%E3%80%82

9. HP Jet Fusion 3D Series vs. Formlabs Fuse 1+ 30W
   https://formlabs.com/compare/hp-jet-fusion-3d-series-vs-formlabs-fuse-1/?wchannelid=ehmpz3codk&wmediaid=g68g25ioam

10. Formlabs Fuse 1+ 30W vs. EOS SLS 3D Printers
    https://formlabs.com/compare/eos-sls-3d-printers-vs-formlabs-fuse-series/

11. Fuse1＋30W/Fuse Sift 3D printing
    https://i-maker.jp/blog/fuse1-sls-3dprinter-35026.html

12. 3D games will be released in 2025.
    https://www.3d-printer.jp/knowledge/classification/

13. The content of the 3D mobile app will be updated in the next 3D.
    https://i-maker.jp/blog/jetting-3d-print-10411.html

14. Color 3D Printing - Stratasys Support Center
    https://support.stratasys.com/en/Applications/Color

15. PolyJet 3D Printers I Stratasys PolyJet J Series | R&D - R&D Technologies
    https://www.rnd-tech.com/3d-printers-product-lines/polyjet/j-series/

16. Binder Jetting 3d printer: the best guide | 3DPTEK - lyafs
    https://www.lyafs.com/binder-jetting-3d-printer

17. Revolutionize metal 3D printing with HP scalable platform configurations
    https://www.hp.com/us-en/printers/3d-printers/products/metal-jet.html

18. The official website - The official website of the website,
    https://contest.japias.jp/tqj25/250164W/type-bjp.html

19. EASYMFG unveils M200Eco and M400Plus metal binder jetting 3D printers for 2025
    https://www.voxelmatters.com/easymfg-unveils-m200eco-and-m400plus-metal-binder-jetting-3d-printers-for-2025/