Skip to main content
SpringerLink
Log in

Selective laser sintering: A qualitative and objective approach

  • Literature Review
  • Modeling And Characterization
  • Published:
JOM Aims and scope Submit manuscript

Abstract

This article presents an overview of selective laser sintering (SLS) work as reported in various journals and proceedings. Selective laser sintering was first done mainly on polymers and nylon to create prototypes for audio-visual help and fit-to-form tests. Gradually it was expanded to include metals and alloys to manufacture functional prototypes and develop rapid tooling. The growth gained momentum with the entry of commercial entities such as DTM Corporation and EOS GmbH Electro Optical Systems. Computational modeling has been used to understand the SLS process, optimize the process parameters, and enhance the efficiency of the sintering machine.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. J.P. Kruth, M.C. Leu, and T. Nakagawa, “Progress in Additive Manufacturing and Rapid Prototyping,” Annals of the CIRP, 47 (2) (1998), pp. 525–540.

    Google Scholar 

  2. E. Radstok, “Rapid Tooling,” Rapid Prototyping Journal, 5 (4) (1999), pp. 164–168.

    Article  Google Scholar 

  3. D. King and T. Tansey, “Alternative Materials for Rapid Tooling,” Journal of Materials Processing Technology, 121 (2002), pp. 313–317.

    Article  Google Scholar 

  4. F. Abe et al., “The Manufacturing of Hard Tools from Metallic Powders by Selective Laser Melting,” Journal of Materials Processing Technology, 111 (2001), pp. 210–213.

    Article  CAS  Google Scholar 

  5. M.W. Khaing, J.Y.H. Fuh, and L. Lu, “Direct Metal Laser Sintering for Rapid Tooling: Processing and Characterization of EOS Parts,” Journal of Materials Processing Technology, 113 (2001), pp. 269–272.

    Article  CAS  Google Scholar 

  6. N.P. Karapatis, J.P.S. Van Griethuysen, and R. Glardon, “Direct Rapid Tooling: A Review of Current Research,” Rapid Prototyping Journal, 4 (2) (1998), pp. 77–89.

    Article  Google Scholar 

  7. H.J. Niu and I.T.H. Chang, “Selective Laser Sintering of Gas Atomized M2 High Speed Steel Powder,” Journal of Materials Science, 35 (2000), pp. 31–38.

    Article  CAS  Google Scholar 

  8. S. Kumar et al., “A Study of Bearing Characteristics of Laser Sintered Iron Powder with Graphite Inclusions,” Proceedings of International Conference on Advanced Materials and Materials Processing (ICAMMP) (West Bengal, India: Department of Metallurgical and Materials Eng., IIT, Kharagpur-721302, 2002), pp. 842–846.

    Google Scholar 

  9. W. O’Neill et al., “Investigation on Multi-Layer Direct Metal Laser Sintering of 316L Stainless Steel Powder Beds,” Annals of the CIRP, 48 (1) (1999), pp. 151–154.

    Google Scholar 

  10. J.P. Kruth et al., “Basic Powder Metallurgical Aspects in Selective Metal Powder Sintering,” Annals of the CIRP, 45 (1) (1996), pp. 183–186.

    Google Scholar 

  11. B. Van de Schueren and J.P. Kruth, “Powder Deposition in Selective Metal Powder Sintering,” Rapid Prototyping Journal, 1 (3) (1995), pp. 23–31.

    Article  Google Scholar 

  12. A. Manthiram, D.L. Bourell, and H.L. Marcus, “Nanophase Materials in Solid Freeform Fabrication,” JOM, 45 (11) (1993), pp. 66–70.

    CAS  Google Scholar 

  13. W.L. Weiss and D.L. Bourell, “Selective Laser Sintering of Intermetallics,” Metallurgical Transactions A, 24A (1993), pp. 757–759.

    CAS  Google Scholar 

  14. D.L. Bourell et al., “Selective Laser Sintering of Metals,” Proceedings of ASME (New York: American Society of Mechanical Engineers, 1994), pp. 519–528.

    Google Scholar 

  15. F.E.H. Tay and E.A. Haider, “Laser Sintered Rapid Tools with Improved Surface Finish and Strength Using Plating Technology,” Journal of Materials Processing Technology, 121 (2002), pp. 318–322.

    Article  Google Scholar 

  16. R. Morgan, C.J. Sutcliffe, and W. O’Neill, “Experimental Investigation of Nanosecond Pulsed Nd:YAG Laser Re-melted Pre-placed Powder Beds,” Rapid Prototyping Journal, 7 (3) (2001), pp. 159–172.

    Article  Google Scholar 

  17. R.H. Morgan et al., “High Density Net Shape Components by Direct Laser Re-melting of Single-Phase Powders,” Journal of Materials Science, 37 (15) (2002), pp. 3093–3100.

    Article  CAS  Google Scholar 

  18. D.T. Pham, S.S. Dimov, and F. Lacan, “The Rapid Tool Process: Technical Capabilities and Applications,” Proc. Inst. Mech. Engrs., 214 (2000), pp. 107–116.

    Google Scholar 

  19. H. Durr, R. Pilz, and N.S. Eleser, “Rapid Tooling of EDM Electrodes by Means of Selective Laser Sintering,” Computers in Industry, 39 (1999), pp. 35–45.

    Article  Google Scholar 

  20. H.M. Zaw et al., “Formation of a New EDM Electrode Material Using Sintering Technique,” Journal of Materials Processing Technology, 89–90 (1999), pp. 182–186.

    Article  Google Scholar 

  21. K. Dalgarno and T. Stewart, “Production Tooling for Polymer Moulding using the Rapidsteel Process,” Rapid Prototyping Journal, 7 (3) (2001), pp. 173–179.

    Article  Google Scholar 

  22. G. Casalino et al., “An Investigation of Rapid Prototyping of Sand Casting Molds by Selective Laser Sintering,” Journal of Laser Applications, 14 (2) (2002), pp. 100–106.

    Article  CAS  Google Scholar 

  23. N.R. Harlan et al., “Titanium Castings Using Laser-Scanned Data and Selective Laser-Sintered Zirconia Molds,” Journal of Materials Engineering and Performance, 10 (2001), pp. 410–413.

    Article  CAS  Google Scholar 

  24. C.L. Liew et al., “Dual Material Rapid Prototyping Techniques for the Development of Biomedical Devices, Part 1: Space Creation,” International Journal of Advanced Manufacturing Technology, 18 (2001), pp. 717–723.

    Article  Google Scholar 

  25. C.L. Liew et al., “Dual Material Rapid Prototyping Techniques for the Development of Biomedical Devices, Part 2: Secondary Powder Deposition,” International Journal of Advanced Manufacturing Technology, 19 (2002), pp. 679–687.

    Article  Google Scholar 

  26. D. Guo et al., “Gelcasting Based Solid Freeform Fabrication of Piezoelectric Ceramic Objects,” Scripta Materialia, 47 (2002), pp. 383–387.

    Article  CAS  Google Scholar 

  27. C.M. Cheah et al., “Rapid Sheet Metal Manufacturing, Part 2: Direct Rapid Tooling,” International Journal of Advanced Manufacturing Technology, 19 (2002), pp. 510–515.

    Article  Google Scholar 

  28. M. Agarwala et al., “Direct Selective Laser Sintering of Metals,” Rapid Prototyping Journal, 1 (1) (1995), pp. 26–36.

    Article  Google Scholar 

  29. M. Agarwala et al., “Post Processing of Selective Laser Sintered Metal Parts,” Rapid Prototyping Journal, 1 (2) (1995), pp. 36–44.

    Article  Google Scholar 

  30. S. Das, “On Some Physical Aspects of Process Control in Direct Selective Laser Sintering of Metals-Parts I, II, III,” Solid Freeform Fabrication Proceedings (Austin, TX: University of Texas at Austin, 2001), pp. 85–109.

    Google Scholar 

  31. J.P. Kruth et al., “Lasers and Materials in Selective Laser Sintering,” Proceeding of 3rd Laser Assisted Nearshape Engineering Conference (LANE-2001) (Erlangen, Germany: Lehrstuhl fur Fertigungstechnologie, 2001), pp. 3–24.

    Google Scholar 

  32. D. Kochan, C.C. Kai, and D. Zhaohui, “Rapid Prototyping Issues in the 21st Century,” Computers in Industry, 39 (1999), pp. 3–10.

    Article  Google Scholar 

  33. N.K. Vail, J.W. Barlow, and H.L. Marcus, “Silicon Carbide Preforms for Metal Infiltration by Selective Laser Sintering of Polymer Encapsulated Powders,” Proceedings of the Solid Freeform Fabrication Symposium, vol. 4 (Austin, TX: University of Texas, 1993), pp. 204–214.

    Google Scholar 

  34. M. Kandis and T.L. Bergman, “A Simulation-based Correlation of the Density and Thermal Conductivity of Objects Produced by Laser Sintering of Polymer Powders,” Journal of Manu. Science and Eng., 122 (2000), pp. 439–444.

    Article  Google Scholar 

  35. M. Berzins et al., “Densification and Distortion in Selective Laser Sintering of Polycarbonate,” Proceedings of the Solid Freeform Fabrication Symposium, vol. 6 (Austin, TX: University of Texas, 1995), pp. 196–203.

    Google Scholar 

  36. H.C.H. Ho, I. Gibson, and W.L. Cheung, “Effects of Energy Density on Morphology and Properties of Selective Laser Sintered Polycarbonate,” Journal of Materials Processing Technology, 89–90 (1999), pp. 204–210.

    Article  Google Scholar 

  37. G. Bugeda, M. Cervera, and G. Lombera, “Numerical Prediction of Temperature and Density Distributions in Selective Laser Sintering Process,” Rapid Prototyping Journal, 5 (1) (1999), pp. 21–26.

    Article  Google Scholar 

  38. M. Berzins, T.H.C. Childs, and G.R. Ryder, “The Selective Laser Sintering of Polycarbonates,” Annals of the CIRP, 45 (1) (1996), pp. 187–190.

    Google Scholar 

  39. J.D. Williams and C.R. Deckard, “Advances in Modeling the Effects of Selected Parameters on the SLS Process,” Rapid Prototyping Journal, 4 (2) (1998), pp. 90–100.

    Article  Google Scholar 

  40. J.C. Nelson et al., “Model of the Selective Laser Sintering of Bishphenol-A-polycarbonate,” Industrial and Eng. Chemistry Research, 32 (1993), pp. 2305–2317.

    Article  CAS  Google Scholar 

  41. Y.P. Kathuria, “Metal Rapid Prototyping via a Laser Generating/Selective Laser Sintering Process,” Proc. Inst. Mech. Engrs., 214, Part B (2000), pp. 1–9.

    Google Scholar 

  42. R. Glardon, N. Karapatis, and V. Romano, “Influence of Nd: YAG Parameters on the Selective Laser Sintering of Metallic Powders,” Annals of CIRP, 52 (2001), pp. 133–136.

    Google Scholar 

  43. M. Shiomi et al., “Finite Element Analysis of Melting and Solidifying Processes in Laser Rapid Prototyping of Metallic Powders,” Inter. Journal of Machine Tools and Manu., 39 (1999), pp. 237–252.

    Article  Google Scholar 

  44. M. Matsumoto et al., “Finite Element Analysis of Single Layer Forming on Metallic Powder Bed in Rapid Prototyping by Selective Laser Processing,” International Journal of Machine Tools & Manufacture, 42 (2002), pp. 61–67.

    Article  Google Scholar 

  45. S. Das et al., “Direct Laser Freeform Fabrication of High Performance Metal Components,” Rapid Prototyping Journal, 4 (3) (1998), pp. 112–117.

    Article  Google Scholar 

  46. C.W. Buckley and T.L. Bergman, “An Experimental Investigation of Heat Affected Zone Formation and Morphology Development during Laser Processing of Metal Powder Mixtures,” Transactions of the ASME, Journal of Heat Transfer, 123 (2001), pp. 586–592.

    Article  CAS  Google Scholar 

  47. H.J. Niu and I.T.H. Chang, “Liquid Phase Sintering of M3/2 High Speed Steel by Selective Laser Sintering,” Scripta Materialia, 39 (1) (1998), pp. 67–72.

    Article  CAS  Google Scholar 

  48. K. Subramanian et al., “Selective Laser Sintering of Alumina with Polymer Binders,” Rapid Prototyping Journal, 1 (2) (1995), pp. 24–35.

    Article  Google Scholar 

  49. “EOS Takes Fine Approach to Laser Sintering,” Metal Powder Report, 56 (3) (2001), p. 18.

  50. D.T. Pham and X. Wang, “Prediction and Reduction of Build Times for the Selective Laser Sintering Process,” Proc. Inst. Mech. Engrs., 214 (2000), pp. 425–430.

    Google Scholar 

  51. P.J. Hardro, J. Wang, and B.E. Stucker, “A Design of Experiment Approach to Determine the Optimal Process Parameters for Rapid Prototyping Machines,” Proceedings of the Joint 5th Inter. Conf. on Automation Technology and Inter. Conf. of Production Research (Taipei, Taiwan: National Chiao Tung University, 1998).

    Google Scholar 

  52. N.P. Karapatis et al., “Thermal Behaviour of Parts Made by Direct Metal Laser Sintering,” Proceedings of 8th SFF Symposium (Austin, TX: University of Texas at Austin, 1998), pp. 79–87.

    Google Scholar 

  53. N.K. Tolochko et al., “Absorptance of Powder Materials Suitable for Laser Sintering,” Rapid Prototyping Journal, 6 (3) (2000), pp. 155–160.

    Article  Google Scholar 

  54. D.L. Bourell et al., “Selective Laser Sintering of Metals and Ceramics,” International Journal of Powder Metall., 28 (4) (1992), pp. 369–381.

    CAS  Google Scholar 

  55. A.H. Nickel, D.M. Barnett, and F.B. Prinz, “Thermal Stresses and Deposition Patterns in Layered Manufacturing,” Materials Science and Engineering A, 317 (2001), pp. 59–64.

    Article  Google Scholar 

  56. K. Boivie, “Limits of Loose Metal Powder Density in the Sinterstation,” Solid Freeform Fabrication Proceedings (Austin, Texas: University of Texas at Austin, 2001), pp. 264–275.

    Google Scholar 

  57. N.P. Karapatis et al., “Optimization of Powder Layer Density in Selective Laser Sintering,” Proceedings of 9th SFF Symposium (Austin, Texas: University of Texas at Austin, 1999), pp. 255–264.

    Google Scholar 

  58. B. Engel and D.L. Bourell, “Titanium Alloy Powder Preparation for Selective Laser Sintering,” Rapid Prototyping Journal, 6 (2) (2000), pp. 97–106.

    Article  Google Scholar 

  59. C.R. Deckard, “Methods and Apparatus for Producing Parts by Selective Sintering,” U.S. patent 4,863,538 (1989).

  60. B.R. Birmingham et al., “Development of a Selective Laser Reaction Sintering Workstation,” Proceedings of Solid Freeform Fabrication Symposium (Austin, Texas: University of Texas at Austin, 1992), pp. 147–153.

    Google Scholar 

  61. U. Behrendt and M. Shellabear, “The EOS Rapid Prototyping Concept,” Computers in Industry, 28 (1995), pp. 57–61.

    Article  Google Scholar 

  62. Y. Song, “Experimental Study of the Basic Process Mechanism for Direct Selective Laser Sintering of Low Melting Metallic Powder,” Annals of the CIRP, 46 (1) (1997), pp. 127–130.

    Google Scholar 

  63. L. Li, K.L. Ng, and A. Slocombe, “Diode Laser Sintering of Compacted Metallic Powders for Desk Top Rapid Prototyping,” Proceedings of 7th European Conference on Rapid Prototyping and Manufacturing (Aachen, Germany: Fraunhofer IPT, 1998), pp. 281–296.

    Google Scholar 

  64. I. Gibson and D. Shi, “Material Properties and Fabrication Parameters in Selective Laser Sintering Process,” Rapid Prototyping Journal, 3 (4) (1997), pp. 129–136.

    Article  Google Scholar 

  65. S. Hur et al., “Determination of Fabricating Orientation and Packing in SLS Process,” Journal of Materials Processing Technology, 112 (2001), pp. 236–243.

    Article  Google Scholar 

  66. A.N. Chatterjee et al., “An Experimental Design Approach to Selective Laser Sintering of Low Carbon Steel,” Journal of Materials Processing Technology, 136 (1–6) (2003), pp. 151–157.

    Article  CAS  Google Scholar 

  67. D. Miller, C.R. Deckard, and J. William, “Variable Beam Size SLS Workstation and Enhanced SLS Model,” Rapid Prototyping Journal, 3 (1) (1997), pp. 4–11.

    Article  Google Scholar 

  68. X. Wang, “Calibration of Shrinkage and Beam Offset in SLS Process,” Rapid Prototyping Journal, 5 (3) (1999), pp. 129–133.

    Article  CAS  Google Scholar 

  69. H.-J. Yang, P.-J. Hwang, and S.-H. Lee, “A Study on Shrinkage Compensation of the SLS Process by Using the Taguchi Method,” International Journal of Machine Tools & Manufacture, 42 (2002), pp. 1203–1212.

    Article  Google Scholar 

  70. J.A. Ramos et al., “Surface Roughness Enhancement of Indirect-SLS Metal Parts by Laser Surface Polishing,” Solid Freeform Fabrication Proceedings (Austin, Texas: University of Texas at Austin, 2001), pp. 28–38.

    Google Scholar 

  71. S. Das et al., “Processing of Titanium Net Shapes by SLS/HIP,” Proceedings of Solid Freeform Fabrication Symposium (Austin, Texas: University of Texas at Austin, 1998), pp. 469–476.

    Google Scholar 

  72. D.T. Pham, S.S. Dimov, and F. Lacan, “Selective Laser Sintering: Applications and Technological Capabilities,” Proc. Inst. Mech. Engrs., 213 (1999), pp. 435–449.

    Google Scholar 

  73. D. Shi and I. Gibson, “Improving Surface Quality of Selective Laser Sintered Rapid Prototype Parts Using Robotic Finishing,” Proc. Inst. Mech. Engrs., 214 (2000), pp. 197–203.

    Google Scholar 

  74. Y.H. Chen and Y. Song, “The Development of Layer Based Machining System,” Computer-Aided Design, 33 (2001), pp. 331–342.

    Article  Google Scholar 

  75. P.M. Lonardo and A.A. Bruzzone, “Measurement and Topography Characterization of Surfaces Produced by Selective Laser Sintering,” Annals of CIRP, 49 (1) (2000), pp. 427–430.

    Article  Google Scholar 

  76. M.M. Sun and J.J. Beaman, “A Three Dimensional Model for Selective Laser Sintering,” Proceedings of Solid Freeform Fabrication Symposium, vol. 2 (Austin, Texas: University of Texas at Austin, 1991), pp. 102–109.

    Google Scholar 

  77. Y. Zhang and A. Faghri, “Melting of a Subcooled Mixed Powder Bed with Constant Heat Flux Heating,” International Journal of Heat and Mass Transfer, 42 (1999), pp. 775–788.

    Article  CAS  Google Scholar 

  78. E. Bollia and R. Glardon, “Numerical Simulation of the Selective Laser Sintering Process,” 16th IMACS World Congress (Lausanne, Switzerland: Swiss Federal Institute of Technology, 2000), pp. 1–7.

    Google Scholar 

  79. Y. Zhang et al., “Three-dimensional Sintering of Two-component Metal Powders with Stationary and Moving Laser Beams,” Journal of Heat Transfer, 122 (2000), pp. 150–158.

    Article  CAS  Google Scholar 

  80. D. Dutta and M. Shpitalni, “Heterogeneous Solid Modeling for Layered Manufacturing,” Annals of the CIRP, 49 (1) (2000), pp. 109–112.

    Google Scholar 

  81. A. Slocombe and L. Li, “Selective Laser Sintering of TiC-Al2O3 Composite with Self-propagating High-temperature Synthesis,” Journal of Materials Processing Technology, 118 (2001), pp. 173–178.

    Article  CAS  Google Scholar 

  82. C.C. Leong et al., “In-situ Formation of Copper Matrix Composites by Laser Sintering,” Materials Science and Engineering A, 338 (2002), pp. 81–88.

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. the Department of Mechanical Engineering, Katholieke Universiteit Leuven, Heverlee, Belgium

    Sanjay Kumar

Authors
  1. Sanjay Kumar
    View author publications

    You can also search for this author in PubMed Google Scholar

Additional information

For more information, contact Sanjay Kumar, Katholieke Universiteit Leuven, Department of Mechanical Engineering, Heverlee, Leuven, 3001, Belgium; +32 16 32 2534; fax 32 16 32 2987; e-mail sanjay.kumar@student.kuleuven.ac.be.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Kumar, S. Selective laser sintering: A qualitative and objective approach. JOM 55, 43–47 (2003). https://doi.org/10.1007/s11837-003-0175-y

Download citation

  • Issue Date:

  • DOI: https://doi.org/10.1007/s11837-003-0175-y

Keywords

Search

Navigation