Layer thickness
0.1 mm
System construction space
350 x 350 x 620 mm
Available materials
polyamide, glass-reinforced polyamide, polypropylene
Optional properties
series material, high-strength, elastic, ...
Lead time
2–5 working days
system in daily use
Selective Laser Sintering (SLS) allows rapid production of detailed functional prototypes or small series from batch sizes of a single unit. We ensure the required product functions from a very early stage, thus accelerating product development and reducing risk. Laser sintering is therefore the shortest path from the idea to market maturity (time-to-market).
In addition, thanks to its almost limitless possibilities, this process has great future potential (layered structure, material can be applied to series parts). Products, molds/tools or prototypes are produced quickly, flexibly and cost-effectively directly from electronic data. This suddenly makes small series, diverse variants or customized user adaptations worthwhile.
Selective Laser Sintering offers numerous advantages, including complete design and construction freedom, the implementation of complex structures, functional integration and tool-free production of prototypes and small series from batch sizes of a single unit.
Layer by layer
Laser sintering is a generative, layer-based construction process. The model is constructed via local sintering or melting of layers of powdered material using focused laser radiation. In contrast to conventional manufacturing processes, all kinds of three-dimensional geometries can be generated with SLS.
(1) Laser
(2) Mirror
(3) Coater
(4) Powder bed
(5) Powder feed
(6) Lowerable platform
(7) Components
The key factor is the material: polyamide, glass-reinforced polyamide and rubber
Our high-tech systems only receive the best original materials, which we have extensively tested. Quality materials and perfectly maintained systems guarantee maximum dimensional and fit accuracy for your pro1o1types. As laser sintering materials, polyamide, glass-reinforced polyamide, rubber and polypropylene are currently available. Request your free sample box.
Get started with polypropylene
Another innovation from 1zu1 is our polypropylene prototypes. Since many products are made from PP, we consistently pursue our goal of getting “1-to-1” to the original. This new service allows 100% use of the original material. Only the manufacturing process used for production of the prototypes differs. This means a maximum component size of 200 mm x 200 mm x 300 mm is possible.
- Optimal coordination of material and machine technology
- Film hinges and fine threads (from size M3) are now also available in polypropylene
- Fast, accurate and true-to-contour production
- 1-to-1 to the original material
We have continuously experimented, discarded and developed to make the best polypropylene on the market available to our customers. Through continuous use in the most diverse projects, we have gradually optimized both the application and the process.
Polypropylene presents us with new challenges in 2019 . After numerous tests, we took the decision to switch to a new type of polypropylene.
PP01 is not only an optimal material for the sintering process, it also comes close to the original material used in the injection-molding process.
Polypropylene PP01 is
- Slightly yellowish, similar to injection-molded PP
- Lighter than water; the material density is 0.89 g/cm³.
- Resistant to greases and almost all organic solvents at room temperature
- Odorless and gentle on the skin, i.e. suitable for applications in the food and pharmaceutical industries
The feedback from our customers regarding PP01 is consistently positive. Our consulting process for this material has clearly also been well-received. Together with our customers, we are therefore always able to offer the optimum material solution for prototypes and series parts. You can also order your free sample box of this material.
- Inquiry: 1. Configure 2. Upload files 3. Complete your inquiry
- Quote
- Job
- Delivery
Selective Laser Sintering (SLS)
1zu1direkt: Our product range can be ordered online ...| Polyamide EOS 2200 (PA) | Polyamide EOS 3200 (PA-GF) | Polypropylene (PP01) | |
|---|---|---|---|
| Average grain size [µm], laser diffraction | 60 | 57 | |
| Bulk density [g/cm³] | 0.435 – 0.445 | 0.63 | |
| Density, laser-sintered [g/cm³] | 0.99 – 1.00 | 1.22 | 0.89 |
| Tensile modulus of elasticity [N/mm²] | 1900 +/-50 | 3200 | 650 |
| Tensile strength [N/mm²] | 50 +/-1 | 51 | 19.5 |
| Bending modulus of elasticity [N/mm²] | 2900 | 684 | |
| Flexural strength [N/mm²] | 22.0 | ||
| Elongation at break [%] | 20 +/-3 | 9 | 24.0 |
| Charpy impact strength [kJ/m²] | 53 +/- 3.8 | 35 | 31 |
| Charpy notch impact strength [kJ/m²] | 4.8 +/-0.3 | 5.4 | 3.0 |
| Ball indentation hardness [N/mm²] | 77.6 +/-2 | 98 | |
| Melting point DIN 53736 [°C] | 172 – 180 | 172 – 180 | |
| Shore D hardness | 80 | 59 | |
| Vicat softening temp. [°C] | 170 | 166 – 179 | > 108 |
| Glass ball weight fraction in [%] | 40 | ||
| Appearance/color | White | Grayish | Yellowish |
| Colorability | Excellent | Limited, not RAL | Not colorable |
The material data has been tested by the Fraunhofer Institute.
Selective Laser Sintering is typically used for components with hard-to-reach areas, functional film hinges and undercuts. To enable us to manufacture these objects precisely and without problems, we have compiled a series of technical guidelines to support your design process.
System-specific parameters
| EOS Formiga P110 | EOS P396 | |
|---|---|---|
|
Maximum recommended component dimensions |
100 x100 x100 mm | 300 x 300 x 600 mm |
|
System construction space |
200 x 250 x 330 mm | 350 x 350 x 620 mm |
| Minimum wall thickness | 0.4 mm (x, y) 0.3 mm (z) | 0.6 mm (x, y) 0.3 mm (z) |
| Minimum gap size Smaller gap widths are not shown. In the case of significantly thicker walls or complex geometries, it is advisable to produce the component cut-out beforehand and adapt the design as necessary. |
||
| Wall thickness < 2 mm | 0.4 mm | 0.7 mm |
| Wall thickness 2 to 5 mm | 0.6 mm | 0.8 mm |
|
Minimum bar diameter D as a function of the bar length l |
D = 0.5 x l | D = 0.8 x l |
Component tolerance per material
| PA2200 and PA3200G | PP | |
|---|---|---|
| Tolerance with edge length ≤ 100 mm | ± 0.2 mm | ± 0.2 mm |
| Tolerance with edge length > 100 mm | ± 0.2 % | ± 0.3 % |
The minimum hole diameters
depend on the wall thickness of the component
| Wall thickness | Hole diameter | |
|---|---|---|
| 0.3 mm | 0.6 mm | |
| 0.6 mm | 0.7 mm |
Additional design guidelines
- Sharp corners and edges are not possible, the minimum radius is 0.3 mm. In exceptional cases, sharp edges are possible in the X/Y plane.
- In the case of very dense/solid components, bubbles may form within the parts due to the amount of energy applied.
- Powder removal must be possible (no completely closed cavities; difficulties arise with thin, curved and long pipes or narrow nozzles that are less than 1.5 mm in diameter).
- Minimum gap (measured as radius) for joints: 0.3 mm. Pay attention to the hinge design (size and shape of the contact surface)! In the case of very solid joints, the required minimum gap dimension may also be (or even above) 1 mm. In case of doubt, consult the 1zu1 Prototypes team (at the RP Center).
- The minimum font size that can be easily imaged is 12 pt (equivalent to a height of 2.8 mm). Ideally, the font should be raised by 0.58 mm.
- For components intended for subsequent assembly, a dimensional difference of at least 0.3 mm must be constructed on the contact surfaces, otherwise a press fit will occur. See the information about component tolerances! Oversizes and subsequent mechanical processing (e.g., tapped holes or bolts) are possible.
- Separation of components with a wall thickness greater than 2.4 mm is possible; the components can be reassembled after manufacture (bonding of tongue and groove). We recommend consulting the 1zu1 Prototypes team to check feasibility with regard to the quality, dimensional accuracy, stability and the optimal solution for the joints.
- Many surfaces on one component/assembly – when used as a dummy, we recommend the creation of an enveloping surface with a wall thickness of 4 mm.
- In practice, a large number of possibilities can be reproduced on our PA2200 and PP Formiga boxes.
Application case for film hinge
only possible with PA2200 and PP
- Wall thickness 0.3-0.45 mm, consider length of the slat for minimum radius (with calculation based on neutral fiber).
- If several film hinges are required, they should, if possible, be oriented in the same plane or parallel to it.
- Due to their stability, film hinges are preferably attached to much thicker walls.
- Components with film hinges feature an open design. The hinge is then a flat surface. The distance between the components corresponds to the neutral fiber of the hinge with a minimum radius of 0.5 mm, e.g.
- Opening angle for hinge: 180 ° -> Distance: 1.6 mm
- Opening angle for hinge: 90 ° -> Distance: 0.72 mm
- Paired film hinges with preload are not sufficiently durable.
Rubber parts
- Maximum component dimensions: 190 x 240 x 300 mm
- Minimum wall thickness: 0.8 mm
- The properties do not correspond to the usual rubber compounds.
- Sufficient time should be allowed for drying after infiltration, depending on the wall thickness. The delivery times are therefore significantly longer (3 to 5 working days).
- Parts that are not completely dry are not dimensionally stable and may be damaged during transport.
- Depending on the storage conditions, dyed parts may tend to discolor after a few weeks.
- Due to the elasticity of the material, it is only possible to check the dimensional accuracy to a limited extent, depending on the geometry.
Example 1:
- Radius = 0.5 mm
- Opening angle for hinge 180°
- Distance 1.6 mm
Example 2:
- Opening angle for hinge 90°
- Distance 0.72 mm
- Paired film hinges with preload do not work (length).
