Material Description

Selective Laser Sintering (SLS) powder is a crucial component in the additive manufacturing process, known for its ability to produce durable and intricate parts with a wide range of material properties. Typically, SLS powders are composed of thermoplastic or thermoplastic-like materials, such as nylon, polyamide, or polystyrene. These powders exhibit excellent mechanical strength, heat resistance, and chemical stability. The powder particles have a consistent and fine particle size distribution, typically ranging from 10 to 100 micrometers, allowing for precise and even sintering. Furthermore, SLS powders often possess good powder flow characteristics to ensure uniform layer deposition in the printing process. The high melting points and low thermal conductivity of these materials make them ideal for the selective laser sintering process, where a laser selectively fuses the powdered layers to create three-dimensional objects. SLS powders come in various formulations, including glass-filled, carbon-filled, or flame-retardant variants, to suit specific applications. These materials offer designers and engineers the flexibility to produce parts with tailored mechanical, thermal, and electrical properties, making them a versatile choice for a wide range of industries, including aerospace, automotive, and medical devices.

Common Industry Applications

SLS powder is crucial in aerospace, automotive, and general engineering sectors for creating complex, high-strength components using selective laser sintering.


3D Printing – Selective Laser Sintering (SLS)

Strength (MPa)
Strength (J/m)
Temp (°C)
0.9 - 1.220 - 5025 - 605 - 30VariesLowVariesMay require
for UV resistance

Design Recommendation

Selective Laser Sintering (SLS) uses a laser to fuse powder material layer by layer. When designing for SLS, consider self-supporting structures to minimize the need for additional supports, which can be challenging to remove from powdered parts. Plan for efficient powder removal post-printing, and maximize the nesting of parts to optimize material usage. Think about the thickness of walls and fine details, as they affect the accuracy of sintering. Be aware of potential thermal issues in larger builds, which can lead to warping or uneven sintering.

Cost Saving Tip

Reducing material waste is central to cost-saving in SLS powder printing. This can be achieved through measures like recycling unused powder and sieving it to remove clumps, ensuring that a significant portion can be reused. Optimizing part nesting to maximize build chamber capacity is another way to minimize material waste. Maintaining the printing chamber’s ideal temperature and humidity levels improves the quality of sintered parts, reducing the need for costly reprints.