Selective Laser Sintering (SLS) 3D Printing Guide 2026

Selective Laser Sintering (SLS) 3D printing is a powder bed fusion process that uses a laser to fuse polymer powder into solid, functional parts layer by layer. SLS 3D printing works by spreading thin layers of material, selectively sintering each cross-section with a CO₂ laser, and repeating until the object is complete. It is widely used for durable polymer parts (commonly nylon) in aerospace, automotive, and prototyping applications due to its ability to produce complex parts without support structures or assembly.

The development of selective laser sintering or SLS technologies began in the 1980s. Dr. Carl Deckard and Dr. Joe Beaman of the University of Texas at Austin (USA) developed the foundations of powder bed fusion technologies. These technologies are capable of manufacturing with multiple materials from polymers to metals, thanks to the application of a laser. When referring specifically to SLS technologies, we are talking about plastic polymers, mainly nylon. However, this has somewhat changed in the last few years, as we will touch on.

In fact, the two doctors, Deckard and Beaman, patented Selective Laser Sintering. Also, they were involved in the creation of DTM Corporation, now part of 3D Systems (since 2001). Since then, many companies specializing in powder melting techniques have emerged, including Farsoon Technologies, specifically specialized in SLS. Finally, it should be noted that a process similar to SLS had been invented and patented back in 1979 by R.F. Housholder but was never commercialized.