Complex, functional geometry, printed without support structures.
Selective Laser Sintering (SLS) is an additive manufacturing process that builds parts from a bed of fine polymer powder, using a laser to selectively fuse each layer's cross-section. The unprinted powder surrounding the part acts as its own support during the build, which means SLS parts don't need dedicated support structures the way many other processes do.
That characteristic is what sets SLS apart: because the powder bed itself holds every part in place, the process is particularly well suited to geometry that would otherwise be difficult or impossible to support — internal channels, interlocking assemblies, and organic or complex shapes that are hard to justify in other processes.
Because there are no support structures to plan around, SLS gives designers more freedom to place features wherever the design calls for them, rather than working around where a support can physically reach. Complex internal geometry, thin interconnected structures and parts nested closely together can all be considered on their engineering merits rather than their printability alone. Wall thickness still matters for structural performance and for allowing trapped powder to be cleared from enclosed cavities after printing, so we review geometry with that in mind before a build.
SLS most commonly uses nylon-based (PA) powders, a material family generally recognised for producing functional parts with a good balance of strength and durability. Within that family, different powder formulations offer different characteristics — some are suited to parts that need rigidity, others to parts that benefit from added toughness — and the parts typically come off the machine with a consistent, slightly matte surface rather than the smoother finish seen in resin-based processes. We'll help you select a suitable powder material based on your part's functional requirements as part of the quoting process.
We use SLS for functional prototypes and engineering parts where geometric complexity or mechanical function is the priority — components with internal features, assemblies that benefit from being consolidated into a single printed part, and prototypes that need to represent real functional behaviour rather than just outward appearance. It's a strong option whenever a design would be constrained by support requirements in other processes.
If your part has complex geometry or needs to perform functionally rather than just look right, share your CAD file with our team and request a quote.
Share your CAD file with our engineering team and request a project-specific quote.