Selective Laser Sintering (SLS)
SLS produces isotropic nylon parts without support structures, ideal for enclosures with snap-fits, living hinges, and complex internal geometry. Run on the Formlabs Fuse 1+ 30W in PA12, PA12-GF, and TPU 90A. Higher-volume nylon also available via HP Multi Jet Fusion (MJF) 4200 and 5200 systems.
SLS and MJF are the powder-bed-fusion processes of choice for production-grade polymer parts. Because unfused powder supports the part during the build, you get geometric freedom that traditional manufacturing simply cannot match: snap-fits, living hinges, fully internal lattices, and conformal cooling channels in a single printed body.
PA12 is the workhorse nylon: biocompatible, environmentally stable, and tough enough to ship as a final production part. PA12 GF adds glass-fiber reinforcement for stiffness and heat resistance. TPU 90A delivers tear-resistant elastomer parts for grips, gaskets, and skin-safe components.
HP MJF is qualified for production-volume nylon: same-day quote, days-to-ship lead times, and unit economics that compete with low-volume injection molding for parts under a few thousand a year.
Built for demanding programs.
Snap-fit, threaded-insert, and weather-sealed housings printed without support, straight off the powder bed.
Internal channels, lattices, conformal cooling, and integrated assembly features impossible to machine or mold.
Lightweight grippers and end-of-arm tooling for production automation cells, durable enough for daily-use service.
Engineering prototypes ready for vibration, thermal-cycle, and load testing before committing to tooling.
Gaskets, grips, vibration dampers, and skin-safe wearables in TPU 90A elastomer powder.
Bead-blasted, dyed, sealed, or painted SLS parts ready for cosmetic or end-use service.
Built on the same AS9100D infrastructure.
Lightweight, dimensionally stable shop aids printed at a fraction of CNC cost: drill jigs, assembly fixtures, inspection gauges, workholding, and end-of-arm tooling.
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Pilot, bridge, and low-volume production, plus end-of-life replacement parts, printed on demand.
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Concept models, functional prototypes, wind-tunnel articles, and design-validation builds, turned around in hours, not weeks, with the same supplier you'll use for production.
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Validated aerospace-grade materials.
General-purpose, biocompatible nylon: the workhorse SLS material for functional prototypes and end-use production.
Glass-filled, biocompatible nylon with enhanced stiffness and heat resistance for demanding industrial environments.
Tough elastomer with high elongation at break and superior tear strength: flexible, resilient, and skin-safe.
Ready to take flight?
Let’s build hardware.
Send us your drawings, or just sketch on a napkin, and your program timeline. Our engineers will provide a rapid quote and deliver flight-ready parts built to your requirements and delivered on schedule.