Laser Sintering is the second most commonly used process after Stereolithography. Whilst accuracy and surface finish are not as good, the real benefit is the functionality that can be achieved. Working with nylon (or a filled nylon), parts demonstrate a very high level of toughness. This functionality is also behind the success that Laser Sintering has achieved in Rapid Manufacturing.

The SLS system consists of a CO2 Laser, a part chamber, and a control system.

SLS rapid prototyping process uses the heat of a CO2 laser to "sinter" or melt powdered thermoplastic materials in subsequent layers. The laser is guided across the part bed by a scanning system and "selectively" sinters the material based on cross-sectional slice information of the 3D CAD data. The platform then descends a layer thickness and the leveling roller pushes material from the powder cartridge across the build platform, where the next cross section is sintered to the previous. This continues until the part is completed. Once the model is complete, it is removed from the part chamber and finished by removing any loose material and smoothing the visible surfaces. The SLS prototypes do not require ant post curing.

The additive layer characteristic of SLS allows the technology to build complex parts and geometries that may not be obtained, or cost effective, through other avenues such as machining.

SLS models and patterns can be produced with the right STL or IGES data from any popular CAD system. SLS is the technology of choice for production of limited volume end use parts, sometimes referred to as Digital Parts Manufacturing. SLS parts are robust and capable of withstanding the rigors of harsh environments and hence are the perfect fit for low volume production of complex, non-cosmetic parts. Unlike SLA, SLS prototyping techniques allow prototypes to be made with material properties closer to that of injection molded pieces (using the DuraFormPA or DuraFormEX material).

The SLS model can also be hand-finished to your specifications. This includes anything from a rough-edged model to a painted real-life replica, depending on your needs.