Before talking about the latest developments, it helps to understand how SLS works. This form of additive manufacturing uses a high-powered laser to fuse small particles of polymer powder, layer by layer, into a solid structure. Unlike FDM printing, which lays down melted filament, SLS works in a powder bed. The laser selectively sinters the particles where needed, while the rest of the powder remains loose, providing natural support for the structure during printing.

This self-supporting method is one of the reasons SLS rapid prototyping has become so popular. It allows for the production of complex geometries, internal channels, and moving parts without the need for support structures.

One of the biggest shifts we’ve seen in recent years is the move beyond prototyping. Thanks to the improvement in material properties and printing accuracy, many industries are now using SLS to create functional parts that go directly into products.

This is especially true in the automotive and aerospace sectors, where lightweight, high-strength components can improve performance and cut down on material costs. Engineers now turn to SLS rapid prototyping not just to test a part’s shape, but also its function under real-world conditions.

In the medical field, custom orthotics, prosthetics, and surgical tools are being made with SLS. The ability to personalise parts based on a patient’s scan and print them in durable, biocompatible materials is changing how healthcare professionals approach care.

Consumer goods have also jumped on board. Brands are using SLS to produce everything from eyewear frames to phone accessories and high-end homeware. The freedom to design complex shapes without tooling limitations opens up massive creative possibilities.