Why Engineers Are Still Talking About SLS (and You Should Be Too)
In the fast-moving world of additive manufacturing, some technologies fade as quickly as they rise. Others quietly evolve and remain indispensable. Selective Laser Sintering (SLS) is the latter; and engineers who need performance over flash know exactly why.
Despite being one of the earliest powder bed technologies, SLS continues to set the standard for durability, design freedom, and production reliability. It’s not nostalgia. It’s engineering logic.
SLS is Still the Benchmark for Functional Parts
If you’re building for real-world conditions — heat, stress, wear, chemical exposure — there are many instances where SLS still leads the pack. It builds in true thermoplastics like PA12, PA11, and filled nylons, not UV-cured resins or thermoplastic fusions that can compromise under load.
Even next-gen competitors using inkjet-based fusing and thermal agents are still chasing the level of material maturity and consistency that SLS has delivered for over two decades. And what about resin-based processes like DLP? While great for dental and design work, they run up against a few issues such as brittleness and UV sensitivity despite some being created specifically for production, and this means they’re simply not in the same category when it comes to engineering-grade strength or longevity.
Strength Without Supports
Everyone knows SLS builds without support structures — no post-processing scars, no restricted geometries, no compromised weak points. But it’s worth remembering that, for engineers working with internal ducting, lattice structures, or snap-fit assemblies, this is a non-negotiable advantage.
Compare that to even the most advanced FDM processes, where support material removal and anisotropic strength are constant design headaches, or to inkjet-fused powder systems, where fusing consistency can vary across part geometries or build orientation.
Repeatability at Scale
Whether you are making one, dozens or hundreds of parts, SLS can be trusted to deliver consistent mechanical properties across the entire batch — build after build.
Some newer polymer fusion technologies use thermal energy in combination with binding agents to produce parts faster — and they offer compelling speed and surface aesthetics. But, they can also face challenges in powder recyclability, internal porosity, and surface finish consistency, especially over larger builds or longer production runs.
Because SLS has matured alongside industries like aerospace, automotive, and medical, it’s better documented, better certified, and better understood — reducing validation risk and speeding up time to market.
Material Versatility That Drives Design
No other polymer process offers the same depth of material choice and real-world resilience. From glass-filled nylons for structural brackets to flexible PA11 offering high impact resistance, SLS is the platform engineers can spec with confidence — and build parts that stand up to heat, chemicals, fatigue, and friction.
From Prototypes to Production – No Shift Required
SLS bridges the gap between fast prototyping and true low-volume manufacturing. And that matters more than ever in today’s supply chain environment. With no tooling, minimal prep, and fast turnaround, SLS makes it easy to pivot, localise, and iterate — without sacrificing performance or quality.
Case in point: When a UK UAV manufacturer needed stronger, lighter parts fast, SLS delivered. Using PA12, they redesigned structural components 50% lighter than aluminium, without compromising strength. The result? A more agile, efficient, higher-performing aircraft — built faster and cheaper than with traditional methods.
Sustainable, Scalable, Smart
As pressure grows to design sustainably, SLS shines here too. With minimal waste, powder reusability, and increasing access to bio-based nylons, it supports circular thinking — without compromising function or speed.
So, SLS Isn’t Just Hanging On — It’s Leading Quietly
It’s tempting to chase the latest acronym. But when you strip away the hype and focus on what matters — performance, consistency, and scalability — SLS still delivers.
Engineers are still talking about it because it still works — for brackets, housings, ducts, tooling, end-use parts and more. And in a field that’s always looking ahead, sometimes the most powerful innovations are the ones that have stood the test of time.
In fact, the global SLS 3D printing market is seeing significant growth. According to a recent report, the market is projected to reach USD 5.8 billion by 2032, exhibiting a compound annual growth rate (CAGR) of 12.88 % during the forecast period of 2023 to 2032.
This growth is being driven by increased adoption across aerospace, automotive, medical, and consumer product sectors. As new materials and machines become available, and post-processing becomes more automated and scalable, SLS is poised to remain a core technology for production-ready additive manufacturing.
Would you like to learn more about our SLS technologies, materials and solutions? Talk to our applications engineers or explore real-world case studies at [Quickparts.com].
