Selective Laser Sintering (SLS) with the ProX SLS 6100...SUPPLY CHAIN Consolidate whole assemblies...

Selective Laser Sintering (SLS)

with the ProX® SLS 6100 PRODUCTION-READY FOR TOUGH, FUNCTIONAL NYLON PARTS

©2018 by 3D Systems, Inc. All rights reserved.

What Can SLS Do For You?


SUPERCHARGE YOUR

MACHINE SHOP

Free up CNC and machinist time

by printing complex plastic

geometry instead of multi-setup

machining.

ACCELERATE PRODUCT

DEVELOPMENT

Go from idea to functional part in

hand in a day. Validate designs in

1/10 the time.

MAKE RADICALLY

BETTER PRODUCTS

Free of the limitations of molding

and CNC, design and produce

radically lighter weight, higher

performance products.

GET MORE FLEXIBLE

PRODUCTION

Make production-quality parts

without tooling. No lead time, and

no up front costs to amortize for

every design.

STREAMLINE YOUR

SUPPLY CHAIN

Consolidate whole assemblies into

single parts to reduce BOMs and

eliminate assembly labor.

PERSONALIZE &

MASS CUSTOMIZE

Skip the limitations of molding and

CNC, while achieving exacting

mechanical properties and

accuracy.

SLS Makes 3D Production Real


INDUSTRIAL

COMPONENTS• Streamlined supply chains

• Flexible production, lots of one

become economical

• Rapid customer responsiveness

AUTOMOTIVE• Compressed product development

cycles

• Functional prototypes that meet heat, strength, accuracy, and mechanical requirements

• Bridge production

• Tool-less manufacturing of injection-mold quality parts

TOOLING

• 3D printed tooling, including

molds, jigs and fixtures is faster

and cheaper than traditional

tooling

AEROSPACE• Significantly faster time-to-market

• Lightweight, high value production

plastic or cast metal parts

• Revolutionizing the supply chain

• Improved assembly through

custom jigs & fixtures

HEALTHCARE• Improved surgical outcomes

through patient-specific surgical guides

• Mass customized production of personalized devices for prosthetics, orthodontics, hearing aids and more

FOOTWEAR

• Mass customized products fit

every customer perfectly

• Lightweight, high-performance

shoes give athletes a crucial

edge

SLS Strength: Real Nylon

SIMILAR TO INJECTION MOLDED PARTS

With a selection of durable polyamide filled and standard materials, SLS parts perform almost identically to injection molded parts. They are true production grade parts that will last for decades.

STRONGER THAN OTHER PRINTED PLASTIC PARTS

No other 3D printing technology makes plastic parts as

strong as SLS. High temperature sintering produces the

best mechanical properties, without voids or other artifacts

that weaken other 3D printed parts.

Prototype housing for

functional testing

Low volume production

automotive part


SLS vs FDM – Process Matters

Flexural Modulus

Flexural Strength

Tensile Modulus

Tensile Strength

Elongation at Break

Impact Strength (unnotched izod)

Heat Deflection Temp

1650 MPa

1630 MPa

60 MPa

48 MPa

1770 MPa

1950 MPa

50 MPa

27 MPa

22%

3%

644 J/m

275 J/m

182 C

98 C

SLS Printed Part in DuraForm ProX PA

FDM Part in Nylon 12, ZX Orientation*

Based on material datasheets

retrieved May 2017

SLS printed part is stiffer

SLS printed part is stronger

SLS printed part is stronger

SLS printed part is superior

*FDM parts are non-isotropic (they have different

mechanical properties in Z). SLS parts are stronger in

the z-axis vs. other 3D technologies.

SLS part is far tougher under tension


SLS Speed

THERE'S NO FASTER WAY TO GET

PRODUCTION-GRADE PLASTIC PARTS

3D Systems SLS

FDM

Injection Molding

Time to create 250 first article parts2 x 2 inch (50 x 50 mm) parts

33 hours (warm up + printing + cooldown + breakout)

240 hours (printing + support removal)

360 hours (2 week tooling lead time + 1 day molding)


No Supports = Fast & Easy Post-Processing

MORE POSSIBILITIES

Parts are supported by

unsintered powder, you don't

need to print support structures,

giving you greater design

freedom.

LOW LABOR COSTS

With no support structures to

remove, operators & technicians

save time.

EFFICIENT PRODUCTION

Large batches of parts are fast

to print and easy to post-

process, making SLS the

choice for production-level

additive manufacturing.

Clean unused powder off parts, and they're done


Smaller Build Volume | More Affordable | Fine Surface Detail Industrial Grade | Large Build Volume | Production Ready

ProX SLS 6100 sPro 60 HD-HS sPro 140 sPro 230

Priced for prototyping

Production capable

Functional parts

Automatic material management

Small scale manufacturing

Functional prototypes

Repeatable production

Large-scale production

Large parts for testing

Wide body construction

Large-scale production

Turbine-sized builds

Functional testing and

manufacturing

LARGE-FRAMEMID-FRAME

3D Systems SLS Product Line


3D Systems SLS Product Line

ProX SLS 6100 sPro 60 HD-HS sPro 140 sPro 230

Maximum Build Volume

15 x 13 x 18 in(381 x 330 x 460 mm)

15 x 13 x 18 in(381 x 330 x 460 mm)

22 x 22 x 18 in(550 x 550 x 460 mm)

22 x 22 x 30 in(550 x 550 x 750 mm)

Material

Options

DuraForm ProX PA DuraForm ProX EX BLK DuraForm ProX GF DuraForm ProX HSTDuraForm ProX AF+ DuraForm ProX FR1200

DuraForm PADuraForm EX BLK DuraForm GF DuraForm HST DuraForm EX Natural DuraForm FR1200DuraForm TPUDuraForm FlexCastForm PS

DuraForm PA DuraForm EX BLKDuraForm GF DuraForm HST DuraForm EX Natural

DuraForm PA DuraForm EX BLKDuraForm GF DuraForm HST DuraForm EX Natural

Layer thickness range: 0.003 - 0.006 in (0.08 - 0.15 mm)

build rate 2.7 l/hr 1.8 l/hr 3.0 l/hr

Recycling & Handling

AutomaticManual (enables

material changeovers)Automatic Automatic


What is the ProX SLS 6100?

• The Mid-Frame SLS printer that has excellent surface finish and fine

detailing, ideal for production quality, but priced for prototyping

• Optimizes price-per-part to deliver a competitive Total Cost of

Operation (TCO)

• Automatic material handling and feeding system saves time and

money

• 3D Sprint software easily plans the builds to maximize space and part

orientation

• 3D Connect capable for proactive and preventative remote

diagnostics

Production Quality, Priced for Prototyping


Unmatched Part Quality

• Excellent surface finish

• Highest resolution and edge

definition

• High accuracy and repeatability

• Uniform part properties


Lower Part Cost20% LOWER TOTAL COST OF OPERATION

• Automated production tools

• High throughput

• 95% material efficiency

• Optimized workflow


Material Quality Control System

The Single MQC

• User-Interface screen lets you define

material blend ratio in 5% steps

• Integrated remote cooling station

• Material tracking data capture

• Downdraft to reduce airborne materials

• Automated Dynamic powder blending

• Supports only one ProX SLS 6100 printer

• Reject and Re-capture powder chutes

• Remote installation up 100M effective length

from printer


Material Quality Control System

The Dual MQC

• The ‘Dual’ MQC does offer more control

over the powder recycling blend allowing

you to set the ratio in 1% steps

• It has 2 material bins for fully automatic

blending and recycling

• Can support 2 printers at once


Production-Grade MaterialsFOR A BROAD SET OF APPLICATIONS

• DuraForm ProX AF+: Aluminum/mineral filled Nylon 12 material

• DuraForm ProX EX BLK: Nylon 11 black material

• DuraForm ProX FR1200: Nylon 12 flame retardant material

• DuraForm ProX PA: Nylon 12 white, biocompatible and food grade

• DuraForm ProX GF: Nylon 12 with glass fibers for flexibility and

durability

• DuraForm ProX HST: Nylon 12 with high temperature resistance


DuraForm ProX AF+MINERAL AND ALUMINUM FILLED NYLON 12 BASED POWDER

• Aesthetic metallic surface finish

• Functional strength at an affordable cost

• Repeatable mechanical properties

• Easily machined and polished

• Excellent stiffness to weight ratio

• Lower costs with higher recyclability


DuraForm ProX AF+APPLICATIONS

• Housing and enclosures

• Plastic parts requiring a metallic finish and good appearance

• High rigidity components and functional assemblies

• Wind tunnel testing parts where stiffness and light weight are

needed

• Jigs and fixtures where high rigidity is required

• Automotive styling parts where a metallic look is needed

(knobs, bezels etc.)


DuraForm ProX EX BLKNYLON 11 BASED POWDER

• Outstanding durability for long-life

• Excellent impact resistance

• Fatigue resistant

• Fuel and oil resistance

• Uniform black coloring

• Derived from sustainable non-petrochemical based plastics

• Replaces injection molded ABS and polypropylene

• For use in real life environments


DuraForm ProX EX BLKAPPLICATIONS


• Vehicle dashboards and grilles

• Automotive bumpers

• Snap-fits, living hinges and connector type parts

• Short production consumer goods/sporting equipment

• Complex designs, especially custom ductwork

• Exhaust and duct systems for aerospace and automotive uses

• Impellers


DuraForm ProX FR1200NYLON 12 BASED FLAME RETARDANT POWDER

• FAR 25.853 compliant

• Passes AITM smoke density and toxicity requirements

• Excellent flame retardancy at 12 and 60 second exposures

• High accuracy and repeatability needed for manufacturing

• Non-halogenated formulation

• Excellent surface quality


DuraForm ProX FR1200APPLICATIONS

• Direct production of aerospace, transportation and consumer

goods application where reliable fire retardancy and reduced

smoke and toxicity are required

• Direct 3D production of aircraft interior parts

– Accelerate changes in cabin designs for in service aircraft

– Eliminate tooling and minimize spare part stocking costs

• Reduce fuel costs with weight optimized design enabled by

additive manufacturing


DuraForm ProX PANYLON 12 BASED POWDER

• Strong, tough thermoplastic material

• Excellent mechanical properties

• Outstanding surface smoothness

• Stable dimensional and mechanical properties

• Exceptional recyclability

• Very high part density

• Biocompatibility: ISO 10993-5 and ISO 10993-10 capable

• Food safe


DuraForm ProX PAAPPLICATIONS

• Functional prototyping and low volume production

parts for:

– Automotive

– Aerospace

– Consumer goods

• Housings and enclosures

• Snap fits and complex assemblies

• Connectors


DuraForm ProX GFGLASS-FILLED NYLON 12 POWDER

• Excellent mechanical stiffness and elevated

temperature resistance

• Dimensionally stable

• Easy-to-process

• Excellent surface finish

• Accurate and repeatable parts

• Machinable and paintable for demonstration parts

• Improved isotropic shrinkage due to glass filler


DuraForm ProX GFAPPLICATIONS

• Strong/rigid prototypes that require elevated stiffness and heat resistance

• Low to mid volume direct manufacturing of end-use parts

• Enclosures and housings that require more stiffness

• Aircraft and motorsports parts

• Sporting goods

• Parts requiring machining or joining with adhesives

• Complex production and prototype plastic parts

• Form, fit or functional prototypes

• Parts requiring stiffness

• Thermally stressed parts


DuraForm ProX HSTFIBER-REINFORCED NYLON 12

• Elevated temperature resistance

• High stiffness and strength to weight

• Anisotropic mechanical properties,

just like fiber-filled

• Non-conductive and RF transparent

• Easy-to-finish surface


DuraForm ProX HSTAPPLICATIONS

• Complex, thin-wall ductwork

• Functional prototypes that approach end-use performance properties

• Appropriate for low- to mid-volume rapid manufacturing

• Medical applications requiring USP Class VI compliance or biocompatibility

• Motorsports

• Aerospace


• Impellers and connectors

• Consumer sporting goods

• Vehicle dashboards and grilles

• Snap-fit designs

• Parts requiring machining or joining with adhesives


3D Sprint for the ProX SLS 6100ADVANCE YOUR WORKFLOW

• High performance auto-nesting

• High density builds

• Sinter Cage structure generator

• Quality check for pre-build verification


Fleet Monitoring

• Customer facing

• Real-time remote monitoring

• Event driven notifications

o Text & email alerts

• Metric rich environment

o Up-time, usage, consumable

use, health of the lasers/print

heads, etc.

Remote Service

• 3D Systems service facing

• Automatically notifies service when

alert conditions occur

• Enables remote investigation for

more precise diagnosis

• No special customer skills set

required

COMING SOON

3D Connect Capable


3D Connect™, A Simplified View

• Edge Gateway synchronizes the

data

• IIOT Platform makes it useful

REMOTE / MOBILECUSTOMER ACCESS

3D SYSTEMS SERVICE TEAM

• LASER HOURS• HEAD PERFORMANCE• SCHEDULED MTC• MORE

Sensor readings

Safe and neutral machine data

Service Tickets

Charts, plots, analytics

Actionable information

COMING SOON


The ProX SLS 6100 in Summary

• Price and performance

– Production quality performance at prototyping price

• Portfolio of 6 production-grade materials

• Strong software platform

– Integrated 3D Sprint and 3D Connect capable

• Automatic material handling, feeding and recycling

through the material quality control (MQC) system


Emirates Uses SLS for Significant Cost

Savings Opportunities of In-Cabin PartsSLS printing with flame retardant nylon material reduces weight of in-cabin video shroud

• Video monitor shrouds are between 9 and 13% lighter

than their conventionally manufactured counterparts

• Emirates optimizes its designs to create fit-for-purpose

parts with an optimized strength-to-weight ratio

• DuraForm ProX FR1200 material:

– FAR 25.853 compliant

– Passes AITM smoke density and toxicity

requirements

– UL certification for consumer goods

• Emirates is in the process of securing Form 1

certification to validate video shroud part design as

approved for aircraft use


Metro Aerospace Introduces 3D Part for Fuel

EfficiencySLS printing provides fuel savings of 4% at cruise with improved aerodynamics

• Metro Aerospace designed microvanes that are

adhesively fastened on both sides of an aircraft’s

fuselage

• Parts designed to reduce drag by reshaping airflow

around the aft cargo door

• Printed with DuraForm® GF, a glass-filled nylon

• Final 3D printed microvanes met the rigorous

standards outlined by the engineers who designed

them


Wiiv Wearables Mass Customization with SLS

100% custom SLS 3D printed production of tens of thousands of shoe soles

• Rapid turnaround of custom shoe soles from

personalized scan data

• SLS build envelope provides the flexibility to stack

parts in a wide variety of configurations

• Enjoy the benefits of 3D production:

– No tooling investment

– Mass customization

– Design freedom

– Fast turnaround


Jay Leno Creates One-of-a-Kind Replacement

Part for EcoJet Concept Car3D Printed Replacement Vent in SLS with high-temperature resistant material

• 3D Systems team helped create a digital workflow to

scan old part and create a design for replacement part

• Printed in Duraform HST, a fiber-filled nylon with

anisotropic mechanical properties

• Ideal for functional prototypes and end-use parts that

require high stiffness and elevated thermal resistance

and has a surface that is very easy to finish


Production Quality with the ProX SLS 6100Transform Your Production Processes with Tool-less Manufacturing

SLS is the 3D printing technology for

real thermoplastic parts without compromise

High performance duct

that's difficult and costly

to mold

Low volume tool-less

manufactured parts

Personalized healthcare

applications


THANK YOU!


Selective Laser Sintering (SLS) with the ProX SLS 6100...SUPPLY CHAIN Consolidate whole assemblies...

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