The document discusses developing an affordable selective laser sintering (SLS) 3D printer with performance comparable to low-cost fused deposition modeling printers. It outlines the design criteria for under $600, including safety, basic functionality, and ability to print a variety of powders. Several potential alternative designs are presented and evaluated based on criteria like safety, cost, speed, and ease of construction.

1. Group 2 | SLS 3D Printer Background
Additive Manufacturing Selective Laser Sintering
- Rapid CAD to 3D Object
- Made of successive 2D layers
- Prototyping benefits to many industries
https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/
Methods
- Stereolithography (SLA) >$5000 http://www.arptech.com.au/slshelp.htm
- Fused Deposition Moulding (FDM) >$500
- Selective Laser Sintering (SLS) >$10000
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

2. Group 2 | SLS 3D Printer Project Problem
Problem Statement:
Develop an SLS 3D printer with comparable cost and performance to small-business FDM 3D
printers currently on the market
SLS Literature:
- Pan/Tilt
There Exists a Need for an - No support during print
- CO2 Laser
- Improved chemical resistance over SLA
Economic SLS 3D Printer for: - Increased density and strength over FDM - Heated Powder
Beds
- Additive manufacturing research
- Material scientists
- Education institutions
- Small businesses
- Hobbyists QuickTime™ and a
decompressor
are needed to see this picture.
Design Criteria:
- Completely safe
- Most basic/simply functional design
http://www.youtube.com/watch?v=28B8NvBFU0E
- Under $600 (supplied funds) Patents:
- Sold for a cost equal to current small-business US Patent #8172562:
3D printer - SLS Printer with translating powder
- Prints large variety of sinter-able powder box
- Thermoplastics, metals, ceramics, organics
(chocolate) US Patent #8187522:
- Robust and reliable hardware and software - Describes the SLS process
- Professional and attractive appearance 1) Lay a layer of powder
2) Irradiate the powder to solidify at required areas
3) Repeat steps 1 and 2 to create a 3D object
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

3. Group 2 | SLS 3D Printer Project Planning
Component
Design
Testing
Deliverables
Potential Contacts
Professor Toyserkani, The University of
or Coherent
Waterloo - Laser company
- 3D printing related research - Bulk chocolate powder
- Borrow high-power laser
- Potential supplies for increased printing time
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

4. Group 2 | SLS 3D Printer Morphological
Chart
Subtractions Solutions
Frame Material Aluminum Plastic Wood
Safety Enclosure Fully Enclosed Laser-safe Plexiglass
Laser Type CO2 Laser Laser Diode
Stationary
Laser
Laser Positioning XY Gantry Pan/Tilt Mirror
Translating
Powder Box
Cylindrical Wedge Radial
Powder Transferring
Roller Slider Dispensing
Optical Lens Vertical
Laser Diameter Adjustment Adjustment
Adjustment
Thermo Electric Cooler
Temperature Control (TEC)
Fan
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

5. Group 2 | SLS 3D Printer Alternative
Designs
Design 1 Design 2 Design 3
Wood Plastic Aluminum
Full Enclosure Plexiglass Enclosure Full Enclosure
Laser Diode Laser Diode Laser Diode
Pan & Tilt XY Gantry XY Gantry
Cylindrical Roller Wedge Slider Wedge Slider
TEC TEC TEC
Laser Diameter Adjustment was removed from design due to difficulty and time constraint
Criteria Priority Table Decision Matrix
Ease of Safet Spee Weig
Criteria Ease Cost Acc. Total
Criteria Safety Constructi Cost Accuracy Speed Weight Total Rank y d ht
on
Weightin
Safety 1 1 1 1 1 5 1 100 90 70 60 50 40
g Factor
Ease of
Constructi 0 1 1 1 1 4 2
on 4x100 5x90 5x70 5x60 8x50 4x40
Design 1 2060
= 400 = 450 = 350 = 300 = 400 = 160
Cost 0 0 1 1 1 3 3
Accuracy 0 0 0 1 1 2 4 Design 6x100 7x90 6x70 6x70 7x50 6x40
2660
2 = 600 = 630 = 420 = 420 = 350 = 240
Speed 0 0 0 0 1 1 5
9x100 8x90 = 8x90 = 8x60 = 6x50 = 7x40 =
Design 3 3240
= 900 720 720 480 300 280
Weight 0 0 0 0 0 0 6
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

6. Group 2 | SLS 3D Printer References
3D Printer Choices for $20,000 or Less, Worldwide Guide to Rapid Prototyping
http://www.additive3d.com/3dpr_cht.htm, Oct 5th, 2012
Rapid Prototyping, Excalibur Engineering Services,
http://www.excalibur-engineering-services.com/rapidprototyping.htm, Oct 13th, 2012
Solid Concepts, Stereolithography (SLA) Gallery,
https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/, Oct 13th, 2012
ARPTECH - Rapid Prototyping Services, http://www.arptech.com.au/slshelp.htm, Oct 13th, 2012
United States Patent and Trademark Office, #8172562, http://patft.uspto.gov/netacgi/nph-Par
ser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-
bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,172,562&OS=8,172,562&RS=8,172,562, Oct 13
th, 2012
United States Patent and Trademark Office, #8187522,
http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2F
f=G&l=50&co1=AND&d=PTXT&s1=8,187,522&OS=8,187,522&RS=8,187,522, Oct 13th, 2012
3D Printing - From CAD file to Complex Metal Part, Layer by Layer - Direct Metal Laser Sintering,
http://www.youtube.com/watch?v=28B8NvBFU0E, Oct 13th, 2012
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar

7. Group 2 | SLS 3D Printer References
3D Printer Choices for $20,000 or Less, Worldwide Guide to Rapid Prototyping
http://www.additive3d.com/3dpr_cht.htm, Oct 5th, 2012
Rapid Prototyping, Excalibur Engineering Services,
http://www.excalibur-engineering-services.com/rapidprototyping.htm, Oct 13th, 2012
Solid Concepts, Stereolithography (SLA) Gallery,
https://www.solidconcepts.com/resources/galleries/stereolithography-sla-gallery/, Oct 13th, 2012
ARPTECH - Rapid Prototyping Services, http://www.arptech.com.au/slshelp.htm, Oct 13th, 2012
United States Patent and Trademark Office, #8172562, http://patft.uspto.gov/netacgi/nph-Par
ser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2Fsearch-
bool.html&r=1&f=G&l=50&co1=AND&d=PTXT&s1=8,172,562&OS=8,172,562&RS=8,172,562, Oct 13
th, 2012
United States Patent and Trademark Office, #8187522,
http://patft.uspto.gov/netacgi/nph-Parser?Sect1=PTO2&Sect2=HITOFF&p=1&u=%2Fnetahtml%2FPTO%2F
f=G&l=50&co1=AND&d=PTXT&s1=8,187,522&OS=8,187,522&RS=8,187,522, Oct 13th, 2012
3D Printing - From CAD file to Complex Metal Part, Layer by Layer - Direct Metal Laser Sintering,
http://www.youtube.com/watch?v=28B8NvBFU0E, Oct 13th, 2012
Andy Vopni Benjamin Cousins Brian Luptak Nima Majidifar