Course Content
Module 1: Introduction to 3D Printing
This section gives an overview of what 3D Printing is and is origins.
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What is 3D Printing?
00:05
3D Printing’s origin…History and Evolution of Additive Manufacturing
Types of 3D Printing Technologies (FDM, SLA, SLS, etc.)
Part 1 Quiz
00:10:00
Module 2: 3D Printers & Materials
This section gives an overview of the various 3D Printer components, 3D Printer types and materials.
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Components of a 3D Printer
Filament Types and Resin Basics
Choosing the Right Printer and Materials!
Module 2 Quiz: Materials and Printer Components
00:05:00
Module 3: 3D Printing File Types
This lesson provides a comprehensive understanding of the myriads of file extensions in the 3D Printing.
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FDM (Fused Deposition Modeling)
SLA (Stereolithography)
SLS (Selective Laser Sintering)
FAM (Fluid Additive Manufacturing)
00:00
Other Technologies.
Module 3: 3D Printing File Types
00:05:00
Module 4: Introduction to 3D Modeling
Start designing your own printable objects with easy-to-use modeling tools. This module introduces you to beginner-friendly 3D modeling software and teaches you how to create objects that are optimized for the printing process.
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Basic Design Concepts
Beginner-Friendly Software (Tinkercad, Fusion 360, FreeCAD)
Getting Started with FreeCAD!
Designing for Printability
Module 5: Slicing and G-Code
Before printing, models need to be sliced into printable layers. Learn how slicing software works, how to adjust print settings like layer height and infill, and how the slicer generates the G-code that your printer uses to build the object.
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Introduction to Slicer Software (Cura, OrcaSlicer and more)!
03:52
Layer Height, Supports, Infill, and Print Settings
Generating and Reading G-code
Module 6: The Print Process
Now it’s time to bring your models to life. Learn how to set up your printer, load materials, calibrate settings, and start your first print. This module also covers how to identify and fix common printing issues like warping or layer shifting.
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Printer Setup and Calibration
Starting Your First Print
Troubleshooting Common Issues
Module 7: Post-Processing
After printing, your model might need some finishing work. Discover how to remove supports, sand rough edges, paint your models, and combine printed parts into assemblies. These techniques can take your prints from good to great.
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Removing Supports
Sanding and Surface Finishing
Painting and Assembly
Module 8: Introduction to 3D Scanning
Learn how physical objects can be digitized using 3D scanning technology. This module introduces different scanning methods, software for cleaning and editing scan data, and how scanning is used in design, repair, and reverse engineering.
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Types of 3D Scanners
Mesh Cleanup
Retopology Applications in Reverse Engineering
Module 9: Real-World Applications
Explore how 3D printing is transforming industries like healthcare, automotive, education, and aerospace. See case studies and examples of how professionals use 3D printing to solve real problems and prototype new ideas.
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3D Printing in Industry, Medicine, and Education
3D Printing in Construction & Housing
3D Printing in Fashion and Art
3D Printing in Defense and Military Applications
Module 10: The Business of 3D Printing
In this module, students explore how 3D printing extends beyond the workshop and into the world of business, sustainability, and emerging markets. From eco-conscious manufacturing to digital entrepreneurship, learners discover how additive manufacturing is reshaping supply chains, product development, and global commerce. The module begins by examining sustainability trends, showing how 3D printing reduces waste, supports local production, and enables environmentally friendly materials. Students then move into the future of additive technologies, including bioprinting, AI-driven design, and off-planet construction. The module also highlights how 3D printing enables new business models—from custom product startups and digital part libraries to contract printing services and hybrid manufacturing workflows. Students gain insight into market opportunities, value propositions, and the strategic use of 3D printing to create value across industries. Whether learners aim to start a business, join an innovative company, or simply understand the economics behind additive manufacturing, this module equips them with the tools and trends that define the future of 3D printing as a business.
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Sustainability and Future Trends
Building a Portfolio or Business in 3D Printing
Complete a Print-to-Finish Project
Submit for Feedback and Certification
Receive Your Certificate and Bonus Gift
Private: 3D Printing Fundamentals.
About Lesson

🧩 Lesson: Selective Laser Sintering (SLS)

✅ Summary

Selective Laser Sintering (SLS) is an advanced additive manufacturing (AM) process that uses a high-powered laser to fuse powdered materials—usually plastics, but also metals and ceramics—into functional, complex 3D parts. In this lesson, you’ll learn how SLS works, explore its unique strengths, limitations, and understand why it’s such a powerful tool in industrial production, prototyping, and beyond.

🎯 Learning Objectives

By the end of this lesson, learners will be able to:

  • Explain how the SLS 3D printing process works

  • Identify the core components and workflow of an SLS machine

  • Understand the advantages and limitations of SLS compared to other 3D printing methods

  • Recognize where SLS fits in industrial and commercial use-cases

  • Evaluate when to choose SLS for a specific application

🔬 1. How SLS Works: The Process

1.1 Powder Preparation

  • A thin layer of powdered material (e.g., nylon, polyamide, or TPU) is spread across the build platform.

  • The build chamber is pre-heated to just below the melting point of the material to make sintering easier.

1.2 Laser Sintering

  • A high-powered laser traces the shape of the first layer of the object.

  • The laser heats the powder particles until they fuse together into a solid layer—without fully melting them.

1.3 Layering Process

  • The platform lowers by one layer height (typically 0.1–0.15 mm), and a new layer of powder is applied.

  • The laser sinters the next layer, which bonds to the previous one.

  • This continues layer by layer until the entire object is formed.

1.4 Self-Supporting Powder Bed

  • No support structures are needed—unsintered powder acts as a natural support.

  • This allows complex geometries, including overhangs, moving parts, and hollow structures.

1.5 Cooling and Post-Processing

  • Once printing is finished, the entire bed cools before part removal.

  • Printed parts are excavated, cleaned (usually via compressed air or sandblasting), and may be dyed, coated, or polished.

🧰 2. Key Strengths of SLS

Strength Benefit
No Supports Needed Design freedom for complex, interlocking parts
Strong Functional Parts Durable, production-quality prints
Versatile Materials Nylon, TPU, composites, metals, ceramics
Batch Production Multiple parts printed simultaneously in one build
Efficient Material Use Unsintered powder is reusable = reduced waste
Minimal Assembly Print assemblies as one object (e.g., hinges, snap fits)

⚠️ 3. Limitations of SLS

Limitation Challenge
Rough Surface Finish Typically grainy; needs sanding or coating
High Equipment Costs Industrial-level machines and environment required
Energy Intensive Continuous heating of the chamber is costly
Post-Processing Required Powder removal, smoothing, sealing may be needed
Limited Material Detail Less resolution than SLA/DLP for fine features
Size Constraints Limited to the printer’s build volume
Material Cost Powders are often more expensive than filaments

🏭 4. Industrial Applications of SLS

SLS is widely used in high-performance sectors due to its combination of strength, detail, and freedom from support structures.

✈️ Aerospace & Aviation

  • Lightweight, strong components

  • Design optimization (e.g., internal channels, brackets)

🚗 Automotive

  • Functional prototypes (ducts, gears, mounts)

  • End-use parts for low-volume production

🏥 Medical Devices

  • Custom-fit prosthetics and orthotics

  • Surgical guides and anatomical models

  • Biocompatible material options

🏭 Manufacturing Tooling

  • Custom jigs, fixtures, and molds

  • Rapid turnaround for one-off tools

🤖 Robotics & Automation

  • Wear-resistant, impact-tolerant moving parts

  • Lightweight robotic enclosures and casings

🛍️ Consumer Products

  • Production-ready enclosures, wearables, and accessories

  • Rapid iterations for user-centered design

📦 Supply Chain Optimization

  • On-demand, local production = reduced warehousing

  • Replacement parts for legacy systems

🧠 5. When to Choose SLS

Choose SLS when your project requires:

  • No support structures (internal channels, overhangs)

  • Durable parts ready for mechanical or thermal stress

  • Batch production of complex parts

  • Reduced post-print assembly

  • Reliable, repeatable accuracy for industrial prototyping

📂 Resources & Further Reading

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