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SLS 3D Printing Service | Stratasys Direct

SLS 3D Printing Service

Parts in as few as 3 days!

ISO9001 & AS9100 QMS | DDTC/ITAR Registered
SLS 3D Printed sample Stratasys Direct

Elevating Precision and Excellence with SLS 

At Stratasys Direct, we're not just leaders in SLS 3D printing; we're pioneers, setting new standards in precision and quality. With over thirty years of SLS experience, our commitment to innovation and excellence has made us the preferred partner for aerospace giants and leaders in industries demanding the highest accuracy and reliability. Our advanced Texas facility boasts North America's largest collection of large-format SLS printers, allowing us to additively manufacture SLS parts with unmatched capacity, accuracy and finish.  

From aerospace ducting to mission-critical components, we specialize in high-requirement SLS projects for end-use part production. Our broad spectrum of Nylon materials, combined with our expert finishing services, allows us to tailor each project to surpass our clients' highest expectations. We proudly hold ISO 9001, AS9100, and ITAR registrations, tirelessly working to advance our material and process validations, consistency, and compliance. Because at Stratasys Direct, we don't just meet standards; we define them.

SLS Material Sample Request

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In the meantime, let us know if you have any questions. We're here to help.

SLS Materials with Uncompromising Quality

Each project is unique, inspiring our diverse selective laser sintering (SLS) material selection. From nylons with fills like FST, ESD, to carbon fiber, these thermoplastics offer a spectrum of properties, ensuring flexibility and enhancing your project with strengths from high ratios to flame retardancy.

 

Key Features
  • High-elongation and impact strength for toughness
  • Qualified for low to mid volume production
Applications
  • Aerospace production parts
  • Best suited for ducting and other applications requiring high elongation and impact strength
  • Motorsports, consumer and sporting goods
  • Prototype living hinge designs
Nylon 11 exhibits superior elongation at break, impact resistance and good memory with excellent surface finish. The material is commonly used in aerospace applications, including functional testing and in production.
Key Features
  • Impact-resistant nylon 11
  • Outstanding toughness
  • Accurate and repeatable manufacturability
  • Toughness similar to molded ABS and polypropylene
Applications
  • Complex ductwork
  • Snap-fit designs
  • Living hinges
  • Thin-walled components
Nylon 11 EX has elevated properties including high impact strength and elongation. The SLS material has fine feature detail and smooth surface finish.
Key Features
  • Polyamide composite with excellent fire retardancy
  • Passes FAR 25.853 12 Second and 30 Second Burn tests
  • Exceptional elongation at break
  • Passes FAR 25.853 Smoke Density test

Applications

  • Aerospace production parts
  • Underhood components
  • Well suited for demanding applications which require flame retardancy
Nylon 11 FR designed for use in commercial, military and civil aircraft requiring fire retardant parts. Material passes FAR 25.853 15 and 60 second vertical burn tests. Material also passes smoke and toxicity requirements. Parts exhibit excellent elongation (21% - 38%) with increased durability and greater flexibility over Nylon 12 PA parts.
Key Features
  • Aluminum filled composite polyamide producing strong, stiff parts with a grey metallic appearance
  • Improved tensile modulus and flex modulus
  • Good wear resistance and detail reproduction
  • Suitable for parts requiring superior surface finish
Applications
  • Illustrative models with metallic appearance
  • Jigs and fixtures like tools and trays used for manufacturing of electronics
This filled SLS material is a composite polyamide-based material, with added aluminum. Nylon 12 AF offers good surface finish and detail reproduction combined with metallic aesthetics.
Key Features
  • Carbon fiber filled Nylon 12
  • Resistance to extreme temperatures and wear
  • Optimal reproduction of detail
  • High stiffness, high tensile strength
  • Electrostatically dissipative
Applications
  • Underhood components
  • Wind tunnel display models
  • Well suited to applications which require superior thermal properties, with maximum performance and an extremely high SLS strength to weight ratio
Nylon 12 CF is a carbon-fiber filled Nylon 12 material that provides increased stiffness and higher heat deflection temperature than many other SLS materials. Nylon 12 CF is also electrostatically dissipative.
Key Features
  • Material passes 60 second vertical burn test
  • Best accuracy & surface finish of available fire retardant materials
Applications
  • Aerospace applications requiring excellent mechanical strength
  • Underhood components
  • Applications requiring fire retardant properties
Nylon 12 designed for use in commercial, military and civil aircraft interiors requiring fire retardant parts. Material passes FAR 25.853 15 and 60 second vertical burn tests. Material also passes smoke and toxicity requirements. Because Nylon 12 FR has lower shrink than Nylon 11 FR, it is better suited for larger parts.
Key Features
  • Glass filled Nylon 12 material
  • Excellent mechanical stiffness
  • Elevated temperature resistance
  • Dimensionally stable
Applications
  • Housings and enclosures
  • Consumer sporting goods
  • Complex prototype plastic parts
  • Form, fit, or functional prototypes
Glass Filled Nylon-12 offers increased modulus for more rigid parts with greater strength. Surface finish and fine feature details are very good and heat deflection temperature (HDT) values are the best of the SLS prototype materials.
Key Features
  • Nylon 12 material with mineral fiber
  • Elevated temperature resistance
  • High stiffness
  • Non-conductive; RF transparent
Applications
  • Structural components
  • Enclosures
  • Load-bearing applications at elevated temperatures
High strength and high temperature mineral fiber-filled plastic parts manufactured with the Selective Laser Sintering (SLS) process. This material offers high tensile strength, high flex modulus, and high heat deflection temperatures and very accurate dimensions for either prototype or production parts.
Key Features
  • Excellent surface resolution/feature details
  • Good chemical resistance
  • Low moisture absorption
  • Produce durable production parts without tooling
Applications
  • Housings and enclosures
  • Impellers, connectors, complex ductwork and snap-fit designs
  • Low volume end-use parts
  • Complex production plastic parts
An unfilled general-purpose Nylon 12 offering good strength and durability with smooth finish, good accuracy, fine feature details and good heat deflection temperatures (HDT).
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Effortless SLS Part Ordering

Ordering your SLS parts online is the fastest way to receive your SLS parts. Upload your design and choose from a myriad of material and finishing options. Our quoting and ordering platform is user-friendly, and our engineering experts are on hand to offer custom quotes. 

Enter NEW30 at checkout for 30% off your online order! Restrictions apply. 

3D Printed SLS Assembled Car | Stratasys Direct

Unmatched Finishing and Assembly for SLS Excellence

Stratasys Direct’s skilled team of finishing and assembly experts adds the perfect touch to your SLS parts. Our comprehensive services, including bead blasting, thermal smoothing, dyeing and painting, ensure that your SLS parts not only meet but exceed expectations in both aesthetics and functionality. Our expert finishing team meticulously inspects each part to guarantee dimensional accuracy and surface finish. In addition, we also offer light assembly to help bring your project to completion.

Man inspecting SLS 3D Printed part using CMM Stratasys Direct

High Standards for SLS 3D Printing

SLS stands out as a preferred choice for parts with tight tolerances and intricate designs, making it one of the most versatile and popular additive manufacturing technologies today. Our unwavering commitment to the highest quality standards in SLS 3D printing ensures that each part meets your specifications consistently. Our robust systems meticulously oversee every aspect, including material handling, recycling, machine maintenance, and process control, guaranteeing material traceability, mechanical property verification, and dimensional accuracy.  From functional prototypes to end-use parts, our SLS experience offers unparalleled precision and accuracy, making Stratasys Direct the provider of choice for SLS 3D printing services.

SLS 3D Printing Design Guide | Stratasys Direct

Selective Laser Sintering Guide

Selective Laser Sintering (SLS) is an additive manufacturing method utilizing a laser to selectively fuse powdered materials, enabling the creation of intricate parts unfeasible through traditional methods. Recent advancements in materials and process control have extended SLS beyond prototyping to viable production applications. Downloading the design guide provides insight into design considerations tailored for SLS fabrication.

Applications of Selective Laser Sintering

SLS stands as the ultimate solution for a myriad of applications, including: 

Selective Laser Sintering Functional Prototyping

Prototypes

Create functional SLS prototypes for testing and design iteration.

SLS Manufacturing Aids | Stratasys Direct

Produce jigs, fixtures, and other tools to streamline production processes.

SLS 3D Printed Production Parts | Stratasys Direct

End-Use Parts

Manufacture durable and functional end-use parts for demanding applications.

Selective Laser Sintering Functional Prototyping

Create functional SLS prototypes for testing and design iteration.

SLS Manufacturing Aids | Stratasys Direct

Produce jigs, fixtures, and other tools to streamline production processes.

SLS 3D Printed Production Parts | Stratasys Direct

Manufacture durable and functional end-use parts for demanding applications.

From one-off prototypes, to low-volume production, we have the experience and engineering know-how to support you

Contact Us

What is Selective Laser Sintering (SLS)?

Selective Laser Sintering (SLS) is a 3D printing process that uses a bed of thermoplastic powder and a laser to create prototypes and functional end-use parts for a wide variety of applications. SLS creates tough and geometrically complex components for batch or serial manufacturing in a wide variety of applications from serialized aerospace production parts to prototypes in consumer applications. SLS provides parts that are strong, heat resistant, and repeatable. SLS was one of the earliest 3D printing processes to be adopted into end-use part production, taking to the skies through aerospace ducting production parts. 

SLS builds robust parts with a wide range of filled nylon materials, making it an ideal process for applications such as duct work, fuel tanks, and brackets, as well as functional prototyping. SLS doesn't require labor to remove support structures as a simple shake of the part will remove the unused thermoplastic powder, enabling true zero-cost complexities in design.

How Does Selective Laser Sintering Work?

SLS (Monikers: Powder bed fusion, LS, plastic laser sintering) builds with a CO₂ laser that melts cross-sections of a CAD design in powdered material.

The CAD model is oriented in space alongside copies of itself or other geometries. The software will then create thousands of layers that make up the 3D objects contained within the build chamber. These layers contain information to tell the equipment where the laser needs to melt material. 

Laser sintering begins by heating its internal build chamber to just below the melting point of the powdered plastic. There is a large chamber of thermoplastic powder, which a recoater blade moves across the top surface to create a very flat surface. A CO₂ laser traces areas of the specified layer where there needed. Once the layer has been melted, the z-stage of the machine will drop slightly allowing the recoater blade to add a very thin layer of material on top of the previously melted layer. Then the laser will trace the areas it needs to melt on this layer, and the process is repeated 100's to thousands of times to create a 3D object.

Once the parts are done building, the powder and the parts need to cool. Once they are ready to be removed, printed parts simply need a little shake or shot with an air hose to remove the support. Much of the support (powder) can be recycled for use in future builds.

Our quality systems ensure consistent handling and recycling of materials along with machine maintenance and process control limits. This provides material traceability, mechanical property verification, dimensional and other performance criteria checks to ensure the parts we deliver meet customer specifications repeatedly.

SLS Resources

Bimotal installed on bike

Bimotal Utilizes 3D Printing for Their E-Bike Conversion Project

Bimotal teams up with Stratasys Direct to create an enclosure to electrify regular bikes using 3D printing Selective Laser Sintering (SLS) technology.

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3D Printing Snare Drums Case Study

Panic! At The Disco drummer Dan Pawlovich tours the world with a 3D printed snare drum.

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superbowl shoes

Article: Super Bowl Shoes

3D printing plays an unprecedented role in the innovative cleats worn by Super Bowl football players.

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Developing Flight-Ready Production Hardware with Laser Sintering

Bell Helicopter turned to us for the production of several components of ECS ducting with Laser Sintering and reaped cost savings and weight reduction.

View more
SLS 3D Printing Design Guide | Stratasys Direct

Selective Laser Sintering Design Guide

Gain a greater understanding of Selective Laser Sintering. Learn about the benefits, limitations, design, and material considerations for SLS. Download the guide.

View more
uav tanks

Innovation in High Power Rocketry Using 3D Printing

Fused Deposition Modeling (FDM) coupled with a higher performance aerospace quality material, we built booster fins, the aft body structure and tailcone for our high power rocket.

View more
Bimotal installed on bike

Bimotal Utilizes 3D Printing for Their E-Bike Conversion Project

Bimotal teams up with Stratasys Direct to create an enclosure to electrify regular bikes using 3D printing Selective Laser Sintering (SLS) technology.

View more
panic at the disco drummer dan pawlovich uses a 3d printed snare drum on stage

3D Printing Snare Drums Case Study

Panic! At The Disco drummer Dan Pawlovich tours the world with a 3D printed snare drum.

View more
superbowl shoes

Article: Super Bowl Shoes

3D printing plays an unprecedented role in the innovative cleats worn by Super Bowl football players.

View more
bell helicopter

Developing Flight-Ready Production Hardware with Laser Sintering

Bell Helicopter turned to us for the production of several components of ECS ducting with Laser Sintering and reaped cost savings and weight reduction.

View more
SLS 3D Printing Design Guide | Stratasys Direct

Selective Laser Sintering Design Guide

Gain a greater understanding of Selective Laser Sintering. Learn about the benefits, limitations, design, and material considerations for SLS. Download the guide.

View more
uav tanks

Innovation in High Power Rocketry Using 3D Printing

Fused Deposition Modeling (FDM) coupled with a higher performance aerospace quality material, we built booster fins, the aft body structure and tailcone for our high power rocket.

View more

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Get efficient and precise injection molded parts with diverse material options at Stratasys Direct's injection molding services.

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Discover how Selective Absorption Fusion (SAF®) 3D printing technology operates and how it can be used to help lower production costs for your next project.

View more
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Learn more about Multi Jet Fusion printing technology and how it can provide a faster, more cost-effective process for 3D-printed parts.

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Get parts using the most widely used form of 3d printing from those who invented FDM®

View more
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P3™, an evolution of DLP 3D printing, produces finely detailed 3D-printed parts using high-performance materials.

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3D Printed Stereolithography SLA part for investment casting

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Learn more about Stereolithography (SLA) 3D printing technology and how it rapidly builds components using a UV laser to cure a photoreactive resin.

View more
3d printed polyjet color shoe

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PolyJet is a 3D printing technology that jets and cures layers of liquid photopolymer to build high-resolution models, prototypes and full color display models.

View more
injection molding machine | Stratasys Direct

Injection Molding Service

Get efficient and precise injection molded parts with diverse material options at Stratasys Direct's injection molding services.

View more

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