Embedded Files
Selective laser sintering is an additive manufacturing (AM) technology that uses a high-power laser to sinter small particles of polymer powder into a solid structure based on a 3D model.
How it works
How it works
The powder is dispersed in a thin layer on top of a platform inside of the build chamber.
The laser scans a cross-section of the 3D model, fusing the particles together to create one solid part.
The unfused powder supports the part during printing and eliminates the need for dedicated support structures.
The platform then lowers by one layer into the build chamber, and the process repeats for each layer until parts are complete.
Materials Used
Materials Used
We currently run Nylon 12 powder which produces parts in a grey colour with a slightly grainy surface finish, but almost no visible layer lines. Sample parts are on show in HPO workshop if you'd like to see how your parts will come out.
Material Properties
Material Properties
Sample part showing different thicknesses, holes and thread possibilities.
Unfinished and painted SLS prints
Drill assembly printed in Nylon 12 Powder. Nylon parts can be easily post-processed to achieve smooth, professional surface finishes.
What can I print on it?
What can I print on it?
Almost any design of part can be printed on the Fuse 1, as it doesn't use support material, so it can produce funky geometries that other printers might not be able to.
The print volume is 165 x 165 x 300 mm.
The main design consideration is that we have to be able to remove the powder after printing, so if you have a hollow structure inside your part without any access holes, it will be full of powder.
This is a great design guide made by the machine manufacturers, which gives advice on wall thicknesses and tolerances.
If you're unsure if the part you're designing will print, come and have a chat with one of the Digital Workshop Technicians and we can give you some advice.
Printing Workflow - How to print using the Formlabs Fuse 1
Printing Workflow - How to print using the Formlabs Fuse 1
Design and Slice
Print and Sift
Post Process
Design your part: Use any CAD software to design your model, and export it in a 3D printable file format (STL, OBJ or 3MF).
Set up the file for printing: Bring your file to one of the Digital Workshops technicians, and we will set up your file on the machine software ready for printing. Note: we usually wait until there are a decent number of parts to print all at once, as this reduces the amount of wasted powder in a print.
Prepare the printer: The technicians will then get the printer ready by loading powder and performing machine checks.
Print: Sit back and relax as the machine does it's magic. The printed parts will be encased in unsintered powder called a 'cake'.
Cooling: The printer then needs to cool down before the printed parts can be removed. Cooling the parts in the cake reduces the likelihood of warping.
Part extraction and powder recovery: Technicians will use the Fuse Sift machine to gently remove printed parts from the powder cake. Any unused powder will be sieved to be reused in future.
Sand blasting: After removing the printed parts, sand blasting is a critical step to fully depowder printed parts and achieve a smooth, powder-free finish.
Optional - Spray painting: Students can then take their parts to spray paint in Sheaf workshop.
How much will it cost?
How much will it cost?
The cost of printing your part(s) will depend entirely on the size of the part.
All prints are charged at a price per gram of powder, and you'll be given a quote before your parts start printing, so you can decide how to proceed.
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