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.

This blog is originally published here: https://quickparts.com/gb/why-engineers-are-still-talking-about-sls-and-you-should-be-too/