Join us for a webinar on SLS technology, where Maciej Broś will introduce the secrets of professional printing from polymer powders using the Formlabs Fuse system as an example. Learn how you can optimize batch production and effectively replace costly injection molding in your business.
Key takeaways from the webinar
- SLS technology involves sintering polymer powder using a laser beam inside a working chamber. The process makes it possible to create complex geometries without the need for support structures, as the unbaked powder itself provides support for the model.
- Models printed with this technology are characterized by high mechanical and chemical resistance, which allows them to be used in outdoor and industrial conditions. An important advantage is their isotropic nature, thanks to which the strength of the detail is almost identical regardless of its orientation with respect to the printing axis.
- SLS printing is most cost-effective in volume production when maximum use is made of the work chamber space through so-called nesting. The ability to stack models in the Z-axis significantly reduces unit cost and time spent on manual handling.
- The complete production ecosystem includes a Fuse 1+ 30W printer, a Fuse Sift station and a Fuse Blast sandblaster, which automates post-processing. This solution minimizes user contact with dust and makes the process of cleaning multiple parts at the same time take only 15-20 minutes.
- A key economic aspect is the recycling of powder, which can be reused in subsequent cycles after printing. As a standard, 30% of the new material is mixed with 70% of the recycled powder, which maintains high mechanical performance while minimizing waste.
- The system is an attractive alternative to injection molding for batches of several hundred units, as it eliminates the high cost of mold construction. The cost of 3D production increases linearly, making it easier to manage budgets with variable designs and smaller volumes.
- Printing a full working chamber on the Fuse 1+ 30W takes about 12-13 hours, regardless of the number of models in it. However, about two hours should be added to this time for the machine’s heating and pre-cooling process before pulling out the parts.
- Working safely with powder requires a properly prepared room with controlled humidity below 50% and a stable temperature. A vacuum cleaner with ATEX-22 approval is also essential equipment to prevent the risk of ignition of polyamide dust in the air.
- PreForm software is free and allows advanced print preparation and accurate cost estimation. It directly supports CAD files (e.g., STEP), allowing textures to be applied to specific surfaces without complicated model conversion.
- The dimensional accuracy of the prints is about 0.5%, and the process is highly repeatable, which is conducive to maintaining quality standards in production. It should be noted, however, that the technology does not allow the print to be held back to accommodate additional elements inside the model, such as magnets or inserts.
Agenda
“Powder 3D Printing. Overview of issues and application examples”
- Introduction to 3D printing technology from polymer powders and presentation of the Formlabs Fuse 1+ 30W system.
- Discuss the principles of SLS technology and the key elements of work chamber construction.
- Presentation of the most important characteristics of the prints, including their mechanical strength, chemical strength and isotropy.
- Guidelines for room preparation, safety systems (ATEX-22) and necessary utilities.
- Analysis of the full production cycle including automated post-processing and material recycling.
- A comparison of the cost-effectiveness and efficiency of SLS printing versus injection molding and FDM technology.
- A session to answer attendees’ questions about technical parameters, operating costs and free PreForm software.
Speaker
Maciej Broś
Expert in powder 3D printing and Formlabs systems. He has conducted dozens of implementations of Formlabs Fuse 1+ 30W systems in Polish companies.
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