Design
Guidlines
For SLS X
Measure
Design
Optimize
(1)Design Considerations
Designing for SLS X requires a balance between creativity and manufacturability. Unlike traditional manufacturing, Selective Laser Sintering enables
complex geometries, internal features, and part consolidation without the need for support structures. However, to achieve consistent print quality,
dimensional accuracy, and mechanical performance, certain design considerations must be followed.
1)Minimum Wall Thickness
Minimum wall thickness is the smallest wall dimension that can be produced in SLS while maintaining
mechanical stability, dimensional accuracy, and thermal balance during the sintering and cooling process.
For SLS X keep this value ≥ 1.0 mm for Reliability
Using thicker walls in SLS parts can significantly improve performance, reliability, and overall print quality.
Walls that are too thin may become fragile, warp during cooling, and they may brake during post processing
2)Minimum Hole Dia
Minimum hole diameter is the smallest internal circular feature that can be accurately formed in SLS while
maintaining dimensionalintegrity and proper powder removal.
For SLS X keep this value ≥ 1.0mm
Keep Circle Dia +0.5 mm in the design, then you will get the exact hole dia
e.g., If the required dia is 5 mm, then in the model keep it 5.5 mm to get an exact hole
If the diameter is too small, holes may close, become undersized, or trap unsintered powder, making
them non-functional.
3)Minimum Drain Hole Diameter
Minimum drain hole diameter is the smallest opening required in a hollow SLS part to allow effective removal of unsintered powder from internal cavities after printing.
For SLS X keep this value ≥ 3.5mm
Unfused powder remains trapped inside enclosed geometries. If drain holes are too small, powder cannot escape efficiently, leading to increased weight, incomplete cleaning, and potential functional issues
Two or more drain holes will be more helpful more bigger hollow parts.
4)Minimum Clearance Between Mating Parts
It is the smallest intentional gap required between two separate components to ensure they do not fuse during the SLS printing process and can move or assemble freely after printing.
For SLS X keep this value ≥ 0.6mm
Ball Soceket Joint
5)Minimum Embossed Details
Minimum embossed details refers to the smallest raised feature (such as text, logos, or patterns) that can be clearly formed and remain legible on the surface of an SLS printed part.
For SLS X, the embossed features are as follows:-
(A) Minimum Embossed Font Height ≥ 3mm
(B) Minimum Embossed Feature Line Width ≥ 0.8mm
(C) Minimum Embossed Feature Height ≥ 1 mm,
6)Minimum Engraved Details
Minimum engraved details refer to the smallest cut feature (such as text, logos, or patterns) that can be clearly formed and remain legible on the surface of an SLS printed part.
For SLS X, the engraved features are as follows:-
(A) Minimum Engraved Font Height ≥ 3mm
(B) Minimum Engraved Feature Line Width ≥ 0.8mm
(C) Minimum Engraved Feature Height ≥ 1 mm,
7)Avoid Stress Concentration Features
Stress concentration points are areas in a part where stress gets highly localized due to sudden changes in geometry, such as sharp corners, thin sections, or abrupt transitions. In SLS parts, these areas are more likely to crack, deform, or fail under load because the force is not evenly distributed.
Here are some features we should avoid while designing parts for SLS:-
(A) Sharp Internal/External Corners & Sharp Edges
(B) Walls without Fillet or Chamfer
(C) Thin Walls
(D) Flat Overhangs
(2)Part Orientation & Placement
1)Minimum Space Between Two Parts
Minimum spacing is the required gap between separate parts in an SLS build to ensure they do not fuse together during printing.
In SLS, the laser heats the powder locally, but that heat does not stay perfectly confined; it spreads into the surrounding area. If parts are placed too close, their heat zones can overlap. This can cause parts to fuse together, deform, or lose dimensional accuracy partially.
For SLS X keep this value
≥ 2mm in XY plane
2)Orient Hollow Parts with Closed Face Upward
For hollow parts that are open from one side, orientation plays a critical role in print quality. The closed surface should be placed facing upward during printing.
Placing the closed surface upward allows the part to build layer-by-layer with proper support from surrounding powder, resulting in better surface quality and dimensional accuracy
3)Utilize The Full Build Volume
In SLS printing, the entire build chamber is filled with powder, whether you print one part or many.
By filling the build space with more parts, you can produce many components in one run without increasing the printing time significantly. This makes the process faster, more efficient, and cost-effective.
4)Control Surface Quality by Orientation
The orientation of a part in SLS printing directly affects how smooth or sharp different surfaces will appear.
Surfaces facing downward (into the powder) tend to have a smoother and more uniform finish. This makes them ideal for curved faces, rounded edges, and visible contours.
Surfaces facing upward may appear slightly rougher but retain sharper edges and finer details. This makes them better suited for features that require precision, such as edges, corners, and detailed geometry.
Smooth Features Downwards
Sharp Features Upward
5)Align Mating Parts In Same Orinetiontion
When designing parts that fit or assemble together, they should be printed in the same orientation within the build.
In SLS printing, slight variations in shrinkage, surface finish, and dimensional accuracy can occur depending on how a part is oriented. If mating parts are printed in different orientations, these variations may not match, leading to poor fit, tight assembly, or excessive clearance.
By keeping the same orientation, both parts experience similar thermal conditions and layer formation, resulting in more accurate and consistent fits.
