Routes to plastic models and prototypes using the SLS(R) selective laser sintering process

Complex three dimensional parts can be manufactured directly from CAD data using the SLSO Selective Laser Sintering process. In addition to the currently used nylon materials, two new materials have been developed for the production of functional models. From an elastomeric polymer, commercially available as Somos 201, highly flexible, rubber-like parts can be produced directly in the Sinterstation system. Also, a new product for producing stiff functional prototypes will be introduced in July, commercially available as VeriForm polymer. Its surface quality and detail definition is superior to the currently used nylon materials while the mechanical properties could be kept at the same level. Comparative data of VeriForm and the nylon materials will be presented. For the production of real technical prototypes injection moulding inserts can be produced by the RapidTool process that can be employed for the production of up to 80,000 parts depending on the injected material and part geometry. By changes in the chemical composition and by new processing parameters, the average cycle time could be reduced from 4 to 5 days down to 2 to 3 days.